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  #1  
Old 09-21-2009, 11:28 PM
Superlifted06FX4 Superlifted06FX4 is offline
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Default Explorer Rear axle swap

I just picked up an axle from a 99 Exploder. 3.55 open and disc brakes so I figured I might as well start a build thread for it.

I already have it stripped down and started cleaning it up. I'm painting the calipers red, the backing plates and housing black, and getting a new diff cover. I still need a new set of gears and an LSD.
Stripped pics, and my findings.
Needs rotors, pads, parking brake shoes and hardware:






Need to clean up my backing plates:


Gears are alright, just not what I need, its a 3.55 open:





Bearings are good too:




Stripped:


I got the mounts cut off, I just have to have a buddy weld the perches on the top, paint it up, and reassemble it.
I did paint the calipers though:



Gutted and cleaned:

The finished total is going to be about $627.99 at the most. It all depends on what I can find at the Pick-n-Pull. Right now the perches and shock mounts are getting welded on. So it will be a while...
Research has told me that the front P-brake cable is the same on both the Exploder and the Ranger, all I need to make it work would be the intermediate and rear cables. I just bought a used R&P, so that should be here soon, and the housing should be finished up within a week. I might be able to pick up a new LSD carrier for cheap at the Pick-N-Pull, so that will help. Picked up new seals and inner pinion bearing just in case I need it. All the bearing are still good so we'll see. Just need rotors, pads, shoes, spring kit, R&P kit, and brake lines.
Started picking up parts to start reassembling my axle when I get it back.
New pads:


New seals and inner pinion bearing:

New brake line:

Got my R&P in yesterday. Now I just need to find someone to install it cheap. And I saw my new shock mounts... 1/4" plate... Heavy as hell, I like em. LOL
Housing:

PS brackets:

DS brackets:

Shock Mounts:


New Seals:

4.10 R&P:




And on a side note, I got a new tailgate and speakers.
Tailgate:




Speakers:


I used the Expo pass. hose on both sides.
Axle to caliper: DORMAN Part # H380528
Truck to axle: DORMAN Part # H38813
Here's the tally of everything so far:
Axle: $109.32
Pinion seal and axle seals: $13.74
Pinion Bearing: $15.40
Wearever Silver pads and 3/16"x60" coated brake line: $24.85
Current Total: $163.31
I don't think thats too bad so far
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  #2  
Old 09-21-2009, 11:34 PM
Downey Downey is offline
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good job man i will put mine up when i get a chance
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  #3  
Old 09-22-2009, 12:32 PM
94_blk4x4 94_blk4x4 is offline
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meh looks ok.. i hope u plan on doing something more with those shock mounts.
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Old 09-24-2009, 11:03 AM
Superlifted06FX4 Superlifted06FX4 is offline
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not even close to done yet.
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  #5  
Old 12-13-2009, 06:05 PM
bagdranger bagdranger is offline
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Be careful with those motor city bearings. I bought that brand hub bearings and had to replace them within like 2 months.
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  #6  
Old 01-01-2010, 08:00 PM
Stumblefoot Stumblefoot is offline
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um did you include R&P in your cost? and labor costs. I can do all the welding and stuff but would take it somewhere for the R&P and gear setup. I just dont have the right tools and experience. Thanks for the part #s There are a few Exploders in our local pick & pull may have to look for one with disks.
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