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  #1  
Old 06-18-2014, 05:25 PM
MotorStuff MotorStuff is offline
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Default MotorStuff's 2003 XLT 4x4 4.0 Build

Finally got around to starting a project log to chronicle the life of my Ranger. Here's what I've done to far.

Got the Ranger in early November of 2013 with 124xxx miles. Was a decent deal and pretty close to me. It was in great shape. The PO had it undercoated and bedlined nice and the dealer fixed some minor issues with it. However, the tires were bald so I had the dealer replace them before picking it up. They are just dealer cheapies, but they've worked fine so far.

Eriks Ipod Photos 12-23-2013 2607.jpg

Eriks Ipod Photos 12-23-2013 2616.jpg

It stayed exactly the same for about a week, when the neighbor kid stepped on the license plate light and snapped it in half. Replaced it with a new one.

It didn't change until that "polar vortex" came, and temperatures were below -40f without wind chill. That caused the slave cylinder to fail, so I decided to have the clutch replaced at the same time. It also turned out that the master cylinder failed and was making air bubbles, so I had that replaced too. I went with LUK for all these parts. I also put in a bigger Walmart battery because the old one was crap.

DSC06255.jpg

I haven't had any problems since the clutch, except for the ABS light coming on once and the parking brake sticking a few times over winter. I did buy a scanguage and mount it on the steering column and also a toolbox for the bed. Last week I decided to plastidip the wheels and they came out great.

DSC07540.jpg

DSC07538.jpg
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2003 Ford Ranger Extended Cab w/ Value Package
4.0 SOHC, 4x4, Stick Shift, 146xxx mi, Some Mods...

Build Thread >>> http://www.fordrangerforum.com/proje...ml#post2172639
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  #2  
Old 06-18-2014, 05:41 PM
MotorStuff MotorStuff is offline
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Default Re: MotorStuff's 2003 XLT 4x4 4.0 Build

Next things to be done this summer will be rust repair, painting headlights, 06 mirrors, 06 corners, T-Bar crank, and some aux lights. Trying to get everything I want done before winter.

Long term mods will be some sort of lift and a 5.0 swap in a few years.

I went out to survey the extent of the rust today. The chassis was undercoated but it didn't hold up through last winter. Seems like its just surface rust though. I went around with a screwdriver and there are no soft spots anywhere. The rear leaf mounts look fine as well. I pulled part of the plastic floor up today and found that its nice and rusty down there as well.

DSC07907.jpg

DSC07909.jpg

Have any of you guys redone the floor with por-15 or something similar? Im also evaluating if por-15 is worth the price for the frame right now. Ill be pulling the bed to coat the frame with something in a few weeks.

DSC07919.jpg

DSC07912.jpg

DSC07921.jpg
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2003 Ford Ranger Extended Cab w/ Value Package
4.0 SOHC, 4x4, Stick Shift, 146xxx mi, Some Mods...

Build Thread >>> http://www.fordrangerforum.com/proje...ml#post2172639

Last edited by MotorStuff; 06-18-2014 at 06:46 PM.
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  #3  
Old 06-23-2014, 05:08 PM
MotorStuff MotorStuff is offline
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I used some full size paper cutouts to decide where to mount my Hella 500FFs I ordered today. They should come in Wednesday and will be mounted behind the grill. My next set of lights will be on the bumper though.

image-3986027319.jpg

image-3609747268.jpg

I bought a nice 30 amp switch from Orielly today and mounted it. I havent heard good things about the Hella switches and wiring, so I will be prepared to redo them too. This switch matches the stock shape and feel and has the same green color too.

I took my ashtray out and hacked most of the metal out of it to fit the switch. Then just a 1/2in hole is required for each switch. Right now I only have one, but it came out so well that I will mount at least two more. With three its should look almost stock.

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File Type: jpg image-1053697545.jpg (62.5 KB, 142 views)
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2003 Ford Ranger Extended Cab w/ Value Package
4.0 SOHC, 4x4, Stick Shift, 146xxx mi, Some Mods...

Build Thread >>> http://www.fordrangerforum.com/proje...ml#post2172639

Last edited by MotorStuff; 07-23-2014 at 03:45 PM.
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  #4  
Old 06-23-2014, 05:28 PM
02Fx4red 02Fx4red is offline
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I like how you made the paper cutouts hahaha.
Smart actually
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  #5  
Old 06-24-2014, 06:21 AM
MotorStuff MotorStuff is offline
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Thanks. I actually had some people think they were real lights when they were behind the grill.
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2003 Ford Ranger Extended Cab w/ Value Package
4.0 SOHC, 4x4, Stick Shift, 146xxx mi, Some Mods...

Build Thread >>> http://www.fordrangerforum.com/proje...ml#post2172639
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  #6  
Old 07-23-2014, 04:20 PM
MotorStuff MotorStuff is offline
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Default Re: MotorStuff's 2003 XLT 4x4 4.0 Build

Put the Hella 500FFs in a few weeks ago. They went in great with no problems.

DSC01009.jpg

I used it to haul a boat and gear on a trip up north. Aside from the shifter coming off, everything went great. Averaged 15mpg loaded up at 70mph.

Today I attacked a lot of the rust on it. I used a 3m paint and rust stripper wheel and a cordless drill to grind all of it off, and then used a rust preventing primer.

Under the door lip
DSC01004.jpg

Tailgate lip
DSC00996.jpg

Rust under and around the rear mud flaps
DSC00990.jpg

DSC00989.jpg
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2003 Ford Ranger Extended Cab w/ Value Package
4.0 SOHC, 4x4, Stick Shift, 146xxx mi, Some Mods...

Build Thread >>> http://www.fordrangerforum.com/proje...ml#post2172639
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  #7  
Old 07-23-2014, 04:22 PM
MotorStuff MotorStuff is offline
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Default Re: MotorStuff's 2003 XLT 4x4 4.0 Build

Sanded and painted the wheel wells
DSC00993.jpg

DSC00991.jpg

Underside of hood
DSC01007.jpg

Front end brace
DSC01008.jpg

Took the spare tire off to inflate, clean, sand and paint
DSC01012.jpg
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2003 Ford Ranger Extended Cab w/ Value Package
4.0 SOHC, 4x4, Stick Shift, 146xxx mi, Some Mods...

Build Thread >>> http://www.fordrangerforum.com/proje...ml#post2172639

Last edited by MotorStuff; 07-23-2014 at 04:26 PM.
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  #8  
Old 07-23-2014, 04:30 PM
MotorStuff MotorStuff is offline
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Default Re: MotorStuff's 2003 XLT 4x4 4.0 Build

DSC01016.jpg

DSC01015.jpg

Nice pics at the end of the day
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2003 Ford Ranger Extended Cab w/ Value Package
4.0 SOHC, 4x4, Stick Shift, 146xxx mi, Some Mods...

Build Thread >>> http://www.fordrangerforum.com/proje...ml#post2172639

Last edited by MotorStuff; 07-23-2014 at 04:33 PM.
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  #9  
Old 07-30-2014, 12:23 PM
MotorStuff MotorStuff is offline
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Default Re: MotorStuff's 2003 XLT 4x4 4.0 Build

https://www.youtube.com/watch?v=0pxc...ature=youtu.be

I hooked up the rear strobe lights today. Now I just need to wire them into the cab.
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2003 Ford Ranger Extended Cab w/ Value Package
4.0 SOHC, 4x4, Stick Shift, 146xxx mi, Some Mods...

Build Thread >>> http://www.fordrangerforum.com/proje...ml#post2172639
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  #10  
Old 07-30-2014, 12:45 PM
03DJ 03DJ is offline
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Subscribed!

Deep Wedgewood Blue, FTW. Was it hard cutting that metal out in the ash tray?
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2003 Ford Ranger FX4: 4.0L V6 | Auto | 4.10s | 265/75R16 BFG AT KO2 | Ion Alloy 174 | Pioneer radio | Alpine Speakers| 06 tails | Thunderbolt turn signal mirrors | Kobalt Toolbox | 22" LED lightbar | Blackout headlights | Headache Rack | 140K miles. DWB!
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  #11  
Old 07-30-2014, 01:18 PM
MotorStuff MotorStuff is offline
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Default Re: MotorStuff's 2003 XLT 4x4 4.0 Build

Quote:
Originally Posted by 03DJ View Post
Subscribed!

Deep Wedgewood Blue, FTW. Was it hard cutting that metal out in the ash tray?
Thanks!

It wasn't that hard, but it took a bunch of patience and two dremel metal cutting discs.
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2003 Ford Ranger Extended Cab w/ Value Package
4.0 SOHC, 4x4, Stick Shift, 146xxx mi, Some Mods...

Build Thread >>> http://www.fordrangerforum.com/proje...ml#post2172639
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  #12  
Old 07-30-2014, 01:35 PM
JJSLAIL22 JJSLAIL22 is offline
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Quote:
Originally Posted by MotorStuff View Post
Next things to be done this summer will be rust repair, painting headlights, 06 mirrors, 06 corners, T-Bar crank, and some aux lights. Trying to get everything I want done before winter.

Long term mods will be some sort of lift and a 5.0 swap in a few years.

I went out to survey the extent of the rust today. The chassis was undercoated but it didn't hold up through last winter. Seems like its just surface rust though. I went around with a screwdriver and there are no soft spots anywhere. The rear leaf mounts look fine as well. I pulled part of the plastic floor up today and found that its nice and rusty down there as well.

Have any of you guys redone the floor with por-15 or something similar? Im also evaluating if por-15 is worth the price for the frame right now. Ill be pulling the bed to coat the frame with something in a few weeks.
I have lightly sanded and painted my whole frame. I used rustoleum rust prevention or something. Turned out real nice. That was over a year ago and looks great still
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2000 Ford Ranger XLT - 4x4 Off Road - 3.0L - 5speed - 4.10 - 3in BL - 2in Torsion Lift - Lokka Front Locker - RCI Skids - Rancho Shocks - Super Start Extreme AGM Deep Cycle Battery - Stock 15x7 Rims - 33x10.50 BFG M/T KM2 w/ Hitch Mounted Spare - Smittybilt XRC8 Winch - On Board Compressor - Hidden Snorkel
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  #13  
Old 07-30-2014, 06:59 PM
MotorStuff MotorStuff is offline
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Default Re: MotorStuff's 2003 XLT 4x4 4.0 Build

Quote:
Originally Posted by JJSLAIL22 View Post
I have lightly sanded and painted my whole frame. I used rustoleum rust prevention or something. Turned out real nice. That was over a year ago and looks great still


Great! That's what I've decided on doing as well. I've been working on soaking the bed bolts and trying to loosen them for the past month. I have 3 of the 6 so far.
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2003 Ford Ranger Extended Cab w/ Value Package
4.0 SOHC, 4x4, Stick Shift, 146xxx mi, Some Mods...

Build Thread >>> http://www.fordrangerforum.com/proje...ml#post2172639
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  #14  
Old 07-31-2014, 08:43 AM
JJSLAIL22 JJSLAIL22 is offline
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Quote:
Originally Posted by MotorStuff View Post

Great! That's what I've decided on doing as well. I've been working on soaking the bed bolts and trying to loosen them for the past month. I have 3 of the 6 so far.
That's pretty bad! Hope they loosen without breaking haha
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2000 Ford Ranger XLT - 4x4 Off Road - 3.0L - 5speed - 4.10 - 3in BL - 2in Torsion Lift - Lokka Front Locker - RCI Skids - Rancho Shocks - Super Start Extreme AGM Deep Cycle Battery - Stock 15x7 Rims - 33x10.50 BFG M/T KM2 w/ Hitch Mounted Spare - Smittybilt XRC8 Winch - On Board Compressor - Hidden Snorkel
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  #15  
Old 07-31-2014, 10:57 AM
MotorStuff MotorStuff is offline
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Me too, but thats why I've been taking my time. They cost almost $20 a piece from what I've heard.
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2003 Ford Ranger Extended Cab w/ Value Package
4.0 SOHC, 4x4, Stick Shift, 146xxx mi, Some Mods...

Build Thread >>> http://www.fordrangerforum.com/proje...ml#post2172639
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