1997 Explorer XLT

[ExplorerTom]

Shayne (accordranger) mentioned I should have my build thread on this forum. Why not. So here it is. This is just copied straight from explorerforums.com, so it's interesting to see my initial stated goal and what it's become now.

Here's my registry. It's not going to really serve as much of a build log or anything, just to help keep track of the (minor) things I do to it along the way.
This is my 1997 XLT. I bought it on 10/13/2010 with 117,500 miles for $2000. It has the SOHC V6, 3.55 rear end and the "Controltrac 4 wheel drive".
This is basically as it was when I brought it home:
http://www.mazdas247.com/members/Tom03es/Explorer/driveway.JPG
Interior shots:
http://www.mazdas247.com/members/Tom03es/Explorer/interior%20-%20LR%20door%20panel.JPG
http://www.mazdas247.com/members/Tom03es/Explorer/interior%20-%20LR%20floor%202.JPG
http://www.mazdas247.com/members/Tom03es/Explorer/interior%20-%20rear%20cargo.JPG
http://www.mazdas247.com/members/Tom03es/Explorer/interior%20-%20rear%20cargo%20shade.JPG
http://www.mazdas247.com/members/Tom03es/Explorer/interior%20-%20rear%20seats.JPG
http://www.mazdas247.com/members/Tom03es/Explorer/interior%20-%20RF%20door%20panel%20before.JPG
http://www.mazdas247.com/members/Tom03es/Explorer/interior%20-%20RF%20seat.JPG
http://www.mazdas247.com/members/Tom03es/Explorer/interior%20-%20RR%20door%20panel.JPG
http://www.mazdas247.com/members/Tom03es/Explorer/interior%20-%20RR%20floor.JPG

Features:
side-step boards
6,000 lb receiver
Ford mudflaps (removed)
hood wind/bug deflector

This Explorer wasn't abused- just a little neglected. The interior is in good shape. The paint isn't in horrible shape- some dings and scratches here and there. All-in-all, good shape for a 13 year old vehicle.

Issues:
cracked and pitted windshield (fixed via post (http://[URL]http://www.explorerforum.com/forums/showpost.php?p=2718120&postcount=61) 61)
inoperable 3rd brake light (fixed via post (http://[URL]http://www.explorerforum.com/forums/showpost.php?p=2769001&postcount=68) 68)
inoperable fog lights (DS housing is smashed on backside and button on dash does not illuminate) (removed)
poor heater output (fixed via post (http://[URL]http://www.explorerforum.com/forums/showpost.php?p=2574827&postcount=3) 3)
coolant temp gauge not moving much (fixed via post (http://[URL]http://www.explorerforum.com/forums/showpost.php?p=2574827&postcount=3) 3)
pulsing front brakes (fixed via post (http://[URL]http://www.explorerforum.com/forums/showpost.php?p=2574807&postcount=2) 2)
slightly sagging rear end (fixed via post (http://[URL]http://www.explorerforum.com/forums/showpost.php?p=2574865&postcount=7) 7)
weak hood lift struts (fixed via post (http://[URL]http://www.explorerforum.com/forums/showpost.php?p=2574849&postcount=5) 5)
weak glass lift struts
weak tailgate lift struts
broken driver's seat recline handle (fixed via post (http://[URL]http://www.explorerforum.com/forums/showpost.php?p=2574868&postcount=8) 8)
leaking rear transfer case output seal (fixed via post (http://[URL]http://www.explorerforum.com/forums/showpost.php?p=2581946&postcount=23) 23)
worn shocks (fixed via post (http://[URL]http://www.explorerforum.com/forums/showpost.php?p=2574865&postcount=7) 7)
alignment out-of-whack (fixed via post (http://[URL]http://www.explorerforum.com/forums/showpost.php?p=2574884&postcount=12) 12)
lack of engine power (fixed via post (http://[URL]http://www.explorerforum.com/forums/showpost.php?p=2574827&postcount=3) 3)

So basically from here on out, this registry will be dedicated to how I have breathed some life back into this thing and some adventures along the way. I've already addressed some of the issues mentioned above. I'll try to post as many pictures as I can, but I know I've already failed on some.

[ExplorerTom]

10/14/2010
New front brake rotors and pads.
I've been a fan of Autozone's Duralast brand for quite a few years. The parts seem to be pretty decent quality. I went with a set of Duralast #54035 rotors and Duralast Gold Cmax #DGC652 pads. The Cmax pads are ceramic pads that come with all new brake caliper hardware (the thin metal clips and whatnot). The Cmax pads also come with a lifetime warranty. I'm not a huge fan of brake pads that last forever (they are wear items afterall) but I decided to give these a try. While I was in there I made sure to clean and lube the slider pins.
Old brakes:
http://www.mazdas247.com/members/Tom03es/Explorer/old%20front%20brakes%20(2).JPG
The old rotors did not come off without a fight. I think I need a bigger BFH.
New brakes:
http://www.mazdas247.com/members/Tom03es/Explorer/new%20front%20brakes%20(2).JPG
Worn front rotors- notice the groove on the outer edge. The old pads still had plenty of life but with the pulsing pedal and grooved rotor, it was time to reset the clock.
http://www.mazdas247.com/members/Tom03es/Explorer/worn%20front%20rotors.JPG
So far, I've been happy with the brakes. They seem to grab quite well and are very smooth. I come from a motorsport background, so I think I know good brakes when I see/feel them.
The ceramic compound of the pads have lived up to their low dust reputation so far. I know ceramic isn't the best material for brake pads since ceramic is an insulator and is fairly hard, but these seem to be working great so far.

[ExplorerTom]

10/15/2010

I've basically got the mindset that everything on this truck is original except for gas, oil and tires so I decided to change the spark plugs. What a PAIN! Thoughts of broken plugs and stripped threads danced in my head as I wrestled with getting them out. Once out, I was pretty sure these were the factory plugs. Most of them were worn to about .090" or so.
http://www.mazdas247.com/members/Tom03es/Explorer/worn%20spark%20plugs.JPG

I put in a set of Autolite double platinum plugs #APP103 gapped to .052". I also decided to put in new plug wires for good measure. For those I went with a set of Duralast #4677 wires. The Duralast wires seemed to be a hair thicker in diameter than the factory wires I pulled out as they were a little stubborn to get into the wire clips around the engine bay.

As a result, the engine seems to respond to throttle inputs MUCH better and accelerates faster.

I also tackled the thermostat and coolant on this day. As mentioned in post 1 in my issues, the heat output was crappy and the temp gauge didn't really seem to move much. When I opened the thermostat housing, I found out why:
http://www.mazdas247.com/members/Tom03es/Explorer/thermostat%20-%20old%20vs%20new.JPG
The plate on the right was laying in the bottom of the thermostat housing. I've never actually seen a thermostat break into 3 pieces before. Surely this thing was original as well. I replaced it with a #13649 from Autozone (don't remember what brand).

The coolant was also flushed. I cringed at the sight of what came out:
http://www.mazdas247.com/members/Tom03es/Explorer/coolant%20flush%20(2).JPG

I refilled with a roughly 55/45 water/coolant mix with a small splash of Red Line Water Wetter. It's no surprise that the heat output in the cabin is great and the temp gauge works like it should now.

[ExplorerTom]

10/17/2010

Changed the PCV. What a pain! Used the boiling water trick to get the plastic tee off the top. I had to grind down the barb on the new PCV to prevent the plastic tee from cracking.

[ExplorerTom]

10/22/2010

New hood lift struts. No more hood slowly closing as I work under the hood.

[ExplorerTom]

10/24/2010

Changed the fuel filter with a Wix #33296.
http://www.mazdas247.com/members/Tom03es/Explorer/fuel%20filter%20(2).JPG
No real reason. Just figured with the history of this truck, wouldn't hurt.

Also took on the messy job of dropping the transmission pan to change the filter and replace some of the fluid. I know the inherent risk of changing the fluid on what's very likely 117,000 mile fluid. The transmission was running fine before and has continued to run fine so far (118,420 miles as of this posting) afterwards. I put in 4 qts of new Mecron V ATF and a 10 oz bottle of Lubegard friction modifier (per Glacier's recommendations).

Sorry, no pictures. I hate ATF. Crap gets everywhere.

The plan is to do it again around Jan/Feb of 2011 and again around Aug 2011 and then stick to 30,000 mile intervals. I'm also planning on adding an external filter and an additional aux cooler soon.

[ExplorerTom]

10/29/2010

The rear of my Explorer was sagging about 1-1.5" from the front. In the future I'd like to tow a popup camper trailer so I'd like to add some carrying capacity to the rear, while getting a mild lift. I got a Pro-Comp add-a-leaf kit.

Sorry, no pictures.

Install was pretty good- just messy. Lots of dirt and silt under the truck. I mostly followed this thread http://www.explorerforum.com/forums/showthread.php?t=97676"]HERE[/URL ([URL)] for the install.

While I had everything apart, I installed some Rancho RS5000 shocks front and rear.

Also no pictures, sorry.

I also did a little TT up front to match the small lift I got out of the AAL in the rear. Afterwards, I had about 33" from the ground to the fenders. Overall ride was stiffer as a result of the AAL and new shocks, but it's all stiffer in a good way.

[ExplorerTom]

10/30/2010

The lack of ability of recline the driver's seat finally got to me. I searched the forums and found that some people have tied a rope around what's left of the broken handle. This sounded like a decent alternative to getting either a junkyard replacement or an expensive redesigned part- either of which could also break.

http://www.mazdas247.com/members/Tom03es/Explorer/interior%20-%20driver%20seat.JPG

It works. It's not great, but it works and the rope can be tucked out of sight.

[ExplorerTom]

11/2/2010

I installed an Amsoil EaA122 nano fiber air filter.

I like the fact that it's a reusable dry filter. I've run K&Ns before but the washing and reoiling can be a pain. And Amsoil seems to be pretty confident that this thing filters better than anything out there.

No pics. It's a stock sized, drop in filter that's got blue filter media. Use your imagination.

Low end response seems to have been increased. I plan on modding the airbox but wanted to get used to this before I went off and changed that too.

[ExplorerTom]

11/3/2010

NEW TIRES! I love the smell of new tires!
I went with 30x9.5r15 BFG KO T/A tires. I also upped the pressure from the door sticker 26 psi (I guess it never got the updated sticker) to 35 psi.
For the past several years with my previous car (2003 Mazda Protege) I've been using summer tires in the non-winter months and winter tires in the winter. These BFG tires come pretty highly regarded and have the snow-flake symbol on them which means they should work better in the snow than a normal all-season tire. Even though I've now got 4wd, I've always had 4 wheel braking and braking is usually where you get into trouble in the snow. Plus they'll go off road.

Switching for a P-rated passenger tire to the LT-rated light truck tire and increased air pressure has made the suspension feel a little more stiff, but it's all good.

I can't wait for it to snow!

The old Goodyear Wrangler RT/S tires weren't worn out- they still had 8/32" of tread remaining They were showing some signs of dry rot cracks though. They were kind of old- molded in the 19th and 20th weeks of 2007. I sold them on craigslist for $100 90 minutes after I originally posted the listing. I got 2 calls and 1 email in that time.
http://www.mazdas247.com/members/Tom03es/Explorer/old%20Goodyears.JPG

[ExplorerTom]

11/5/2010

Got an alignment. The steering wheel wasn't quite straight while driving and I thought I noticed some odd wear on the old Goodyears. Since I got new tires, I wanted to make sure I wasn't going to ruin them prematurely.

Turns out the right side toe was out of spec.

Now the wheel is nice and straight and everything is within spec.

[ExplorerTom]

11/10/2010

New Radiator cap.

The old one (Motorcraft- so again, likely original) didn't seem to be sealing anymore. I've been losing coolant slowly since I bought the truck. The cap didn't seem to sit really tight and the underside of the lip would be wet and the smell of hot/burnt coolant seemed always present.

The new one (pic to follow) immediately seemed to sit more securely.

[ExplorerTom]

11/12/2010

Took it to a local 4x4 repair shop to get the rear transfer case seal replaced. I tried to do it myself but I couldn't get the nut on the output flange to break free. My air tools are weak.

Shop calls around 1 with bad news- appears there is a bunch of play in that shaft and there was metal in the fluid when they drained it. Now that I've done some forum searches, it appears this is somewhat of a common problem on the 4405 transfer case.

Crap.

I told them to tear into it. Won't hear back on it until Monday. He said worst case scenario would be like $1,100 and best case would be $500. Sounds like it will be done one way or another on Monday though.

And they said my lower ball joints have some excessive play. I'll do those myself.

[ExplorerTom]

11/16/2010

Got the truck back today. Finally.

Unfortunately, it was worst case scenario and then some. $1,485.

Ouch.

Basically they said that the rear output shaft bearing was free to move in and out along the output shaft. I'm not sure if this is how the factory design is or not. But as the bearing slid back and forth along the raceway, it scored and pitted the raceway pretty bad in the rear transfer case half.
Their solution- get a re-designed rear transfer case half. The new design prevents the bearing from moving in and out. They claim the transfer case will be problem free from now on. They filled it with some kind of fully synthetic Castrol 5w30 transfer case fluid. I have a 24 month/24,000 mile warranty.
They said the rest of the truck is pretty solid though.

(I should have gone with a manual transfer case swap......)

[ExplorerTom]

11/28/2010

Airbox Mod

I was outside waiting to see what/if the Bronco game flyover would be. I live on the south side of the metro area and that's usually where the pre-game flyovers stage. Today it was 4 F-16s. Last time it was a B-2 bomber.

Pulled out the airbox. It was seriously stubborn to get the front lower plug out. And it was SUPER filthy. I washed it inside and out.
Then I broke out the 3/4" drill bit.
http://www.mazdas247.com/members/Tom03es/Explorer/airbox%20mod.JPG
http://www.mazdas247.com/members/Tom03es/Explorer/airbox%20mod%20(2).JPG

I decided to leave the "horn" in place and only drill 2 of the 4 sides. I think I may come back in for a second attempt and add some reflective insulation to the engine sides. I've also been known to wrap the intake tube.

No driving impressions yet- Bronco game is on.

[ExplorerTom]

12/7/2010

Front Differential Fluid Change

I was only able to get about 24 oz of fluid out (of about 56 oz). I bought some stupid siphon bulb thing at O'Reilly (recommended by the guy at the store) and I wasn't impressed. Harbour Freight has a suction gun that I'm going to give a try. I refilled it with new Red Line 75w90 gear lube. The color of the fluid that came out was nothing like what I put in- it was black. The Red Line fluid is a see-through amber color.

I'm going to do the rear on Friday (day off!!). I'll try to get pictures.

Sorry, no pics. I've added gear lube to my list of hated automotive fluids. That stuff is nasty!

[ExplorerTom]

12/10/2010

Rear diff fluid change.

Yuck.

Again, in my quest to freshen up what I can on this truck, I decided to tackle the rear diff. The fluid was pretty dark but I thought I saw 2 different colors of RTV on the cover so it's possible that the fluid has been changed. But there was some fluid weeping out of the bottom of the cover so it was time.

Here's the cover after I took it off:
http://www.mazdas247.com/members/Tom03es/Explorer/rear%20diff%20fluid%20-%20cover%20before.JPG
http://www.mazdas247.com/members/Tom03es/Explorer/rear%20diff%20fluid%20-%20cover%20inside.JPG
Open Diff "goodness????......":
http://www.mazdas247.com/members/Tom03es/Explorer/rear%20diff%20fluid%20-%20diff%202.JPG
http://www.mazdas247.com/members/Tom03es/Explorer/rear%20diff%20fluid%20-%20diff%203.JPG
I decided to paint the diff cover something subtle. Unfortunately I didn't really plan ahead and had to rely on what I already had. Gloss black is subtle, right?:
http://www.mazdas247.com/members/Tom03es/Explorer/rear%20diff%20fluid%20-%20done.JPG

Eh, it'll work.

I filled it with some Red Line 75w140. What a PITA filling the diff is. I spilled some. OK, I spilled alot. I need to get a better funnel before I do this again.
*Also, I photobombed the first post with some interior shots. Nothing special, but probably enough to make Joe Dirt break down crying.

[ExplorerTom]

12/24/2010

Transfer case is leaking again. Gonna call the shop on Monday. Should be covered under warranty. It only seems to leak when stopped on an upward incline.

[ExplorerTom]

12/28/2010

Got the truck back the other day- the VSS was leaking. And not leaking around the o-ring, but the sensor itself was cracked...... probably from when they were servicing the TC last. They didn't charge me labor, just for the part. $66.21 and it was mine again.

The shop also said my ball joints were "really bad- dangerously bad" this time. So I bought the Moog's from Advance Auto and rented the ball joint press. I followed the sticky (LINK[/URL (http://[URL]http://www.explorerforum.com/forums/showthread.php?t=188225)]) and it went pretty well. I wasn't able to seat the new ball joint using the floor jack, but I could configure the ball joint press to press them in.

[ExplorerTom]

12/31/2010

Well, we got our first significant snowfall of this winter season- 4-5" or so accompanied with some bitter cold. The Explorer did fine. I took it out for some donuts at the local high school parking lot. Good times!

The BFG tires- honestly, not terribly impressed. They have the "mountain snowflake symbol" but they still aren't as good as actual dedicated winter tires. My Saturn VUE with Michelin X-Ice tires or my former Mazda Protege with Hankook iPikes are both more confidence inspiring in the snow than my Explorer with the BFGs.

Oh well, just slow it down when it gets slippery.

[ExplorerTom]

1/7/2011

Took the dog for a drive in the mountains. She's not a very good road companion. I swear she throws up every time we go for a drive in the mountains. This time was no different. Luckily, that cargo mat saved the day. As soon as I smelled the throw up, I pulled over, pulled the mat out, shook the chunky dog puke off, washed it off with some of the water I brought and it was good as new! I love that mat.
http://www.mazdas247.com/members/Tom03es/Explorer/Reynolds%20Park%20(2).JPG
http://www.mazdas247.com/members/Tom03es/Explorer/Reynolds%20Park.JPG

You can see that I've been slowly pulling the pin striping off. And I haven't washed it since.

After this, I drove on some really wash boarded, and muddy road. Almost got hit by a Chevy dually. No pics as of yet. Nothing major anyway.

[ExplorerTom]

1/16/2011

Cleaned the MAF and IAT sensors. Neither were noticably dirty. The guy that I bought this thing from said that after he bought it, the air filter was black- like severely overdue for a changing (another thing that's quite possible was original from the way he described it). So I figured the sensors might have picked up a little dirt and crud over time.

I bought some CRC MAF cleaner and sprayed them down. I didn't take the MAF out of the MAF housing- I don't have the security torx bits. The back side of the IAT was cloudy.

The CRC can claims that they gaurantee a 3-10 whp gain, with an asterisk. I never bothered to hunt down what the asterisk said. I'm not holding my breath.

Also noticed that the passenger side valve cover breather hose was disconnected at the valve cover. Hmmmmm.......

The truck drives........ the same. Hoping to maybe pick up an mpg or 2 or 3 or 4 or 5 or........ I seem to be averaging 16 or so right now. We'll see.

[ExplorerTom]

1/30/11

Headlight restoration.

The headlights were a little cloudy and pitted- no surprise really for a vehicle of this age. I tossed around the idea of get 2 new headlight assemblies, but decided that about the price of one new one, I could bring these back to nearly 100% with that 3M Headlight Restoration Kit. I picked one up at Autozone for about $20.

It's a fairly easy job- follow the instructions and you'll be fine.

Before:
http://www.mazdas247.com/members/Tom03es/Explorer/headlights%20-%20before.JPG
http://www.mazdas247.com/members/Tom03es/Explorer/Headlights%20-%20LH%20close%20before.JPG
http://www.mazdas247.com/members/Tom03es/Explorer/headlights%20-%20RH%20close%20before.JPG

After about 20 minutes of work:
http://www.mazdas247.com/members/Tom03es/Explorer/Headlights%20-%20after.JPG
http://www.mazdas247.com/members/Tom03es/Explorer/Headlights%20-%20LH%20close%20after.JPG
http://www.mazdas247.com/members/Tom03es/Explorer/Headlights%20-%20RH%20close%20after.JPG

I'm satisfied. They aren't perfect, but they are better than what I started with. I haven't had a chance to try them out at night yet.

[ExplorerTom]

3/18/11 122,841 miles

Rear wheel bearing and seals.

While replacing the rear rotors and pads last weekend, I noticed the right wheel bearing seal was leaking. I put the pad/rotor replacement on hold and tackled the bearings/wheel seals today. I wasn't thrilled that I had to crack open the pumpkin after just filling it with expensive Red Line gear oil a couple months ago, but such is life. I've never had any experience pulling rear axles before so I was a little worried, but it was really easy.

Once I got a proper slide hammer with an bearing puller attachment (the one I got from Autozone was crap, Advanced Auto had a nearly brand new tool that worked great), the old bearings and seals popped out fairly easily. The new bearings went in easy with a VERY large socket I had laying around from a previous axle seal install. I managed to eff up one wheel seal so I had to have a friend take me to the store to get a new one.
................I'll finish this update later.......

[ExplorerTom]

Pics (I didn't take too many because gear lube is nasty and I don't want to get it all over my camera):
http://www.mazdas247.com/members/Tom03es/Explorer/axle%20removed.JPG
http://www.mazdas247.com/members/Tom03es/Explorer/axle.JPG
http://www.mazdas247.com/members/Tom03es/Explorer/diff%20with%20pin%20removed.JPG

The new funnel I got has a nice bendy tube attached to it which made filling the rear diff a piece of cake compared to how I did it before.

I also painted the rear bumper trim. I am trying to consolidate the colors on the exterior. What I've got so far:
Red - duh!
Black - tires, mirror, trim around windows
Chrome/aluminum - bumpers and wheels (they aren't quite the same but pretty close)
Purply/grey - bumper trim, running board steps
My plan is to only have 3 exterior colors.

Before:
http://www.mazdas247.com/members/Tom03es/Explorer/interior%20-%20rear%20cargo%202.JPG
After:
http://www.mazdas247.com/members/Tom03es/Explorer/painted%20rear.JPG

I used some Rustoleum Truckbed Liner. One can was only enough to do the 4 pieces along the back. Even though it's not perfect (some runs here and there), it looks TONS better.

I also installed the trailer wiring harness I bought from Joe Dirt many moons ago. I tried to remove the bumper to do it (and to aid in painting) but the right rear of the bumper got crunched just enough to make it an interference fit. Instead I just popped off the top bumper trim.

[ExplorerTom]

3/27/2011

Bought a 1996 Jayco popup camper today. 10 foot box. Pics to come in the following days. This is basically the reason I bought my Explorer.

Excited!

[ExplorerTom]

Here's our new toy. The weather is looking good for this weekend so who knows, maybe we'll take it out for a test spin.
http://www.mazdas247.com/members/Tom03es/Explorer/camper%20-%20towing.JPG
http://www.mazdas247.com/members/Tom03es/Explorer/camper%20-%20towing%20(2).JPG

It tows well. Haven't had it up to any significant speed- maybe 45 mph. It's wide, that's for sure. It's a couple inches wider on each side than the truck.

We set it up quickly when we got it home just 'cuz.
http://www.mazdas247.com/members/Tom03es/Explorer/camper%20-%20setup.JPG

We didn't tuck any of the sides down- we just set it up quickly so the kids could check it out. I can't decide if the faded/peeling decals are going to stay or if I'm going to remove them.

For the mean time, it's going to sit in the garage until I can get it registered, insured and a storage place set up for it. I think I'm also going to do some touch ups here and there. It takes up a TON of space in the garage too.
http://www.mazdas247.com/members/Tom03es/Explorer/camper%20-%20garage.JPG

I'm sure there will be plenty of posts about the adventures with the camper.

[ExplorerTom]

4/15/2011 Tax Day!

Started off by changing the oil and rotating the tires.

Next I decided to finally tackle painting the rest of the trim pieces and the side steps/running boards. They both had a hint of purple in them as seen an any of the pictures I've previously posted. I never liked it.
http://www.mazdas247.com/members/Tom03es/Explorer/painting%20trim%20-%20front.JPG
http://www.mazdas247.com/members/Tom03es/Explorer/painting%20trim%20-%20front%20corner.JPG
http://www.mazdas247.com/members/Tom03es/Explorer/painting%20trim%20-%20step%20before.JPG
http://www.mazdas247.com/members/Tom03es/Explorer/painting%20trim%20-%20step%20painted.JPG
http://www.mazdas247.com/members/Tom03es/Explorer/painting%20trim%20-%20painted%20right%20rear%20iso.JPG
http://www.mazdas247.com/members/Tom03es/Explorer/painting%20trim%20-%20paint%20left%20side.JPG

I was going to get some pics with all the tape removed, but well..... I didn't. Later, I'm sure.

And then to top it off, I forgot to put the oil cap back on. Smooth- real smooth. Now the fire blanket on the underside of the hood is partially soaked in oil.
Awesome.

[ExplorerTom]

4/29/11

New windshield was installed today! While I don't have any pictures of the cracked windshield, just imagine a windshield with 3 cracks- one going from the left to the center in the lower part of the windshield, one going across the right to center in the upper part of the windshield, and one vertical right down the center.

It is SO nice to have a clean view while driving. While the cracks weren't really in my view, the windshield was also pitted pretty badly.
http://www.mazdas247.com/members/Tom03es/Explorer/new%20windshield.JPG

And a new windshield means new wipers! I've used these Bosch Icons on 3 different vehicles now and have liked their performance on all of them. They wipe very well the first time and rarely streak.
http://www.mazdas247.com/members/Tom03es/Explorer/wiper%20-%20old%20and%20new.JPG
http://www.mazdas247.com/members/Tom03es/Explorer/wipers%20-%20icons.JPG

Also went and found some mud puddles to play in. When the brand new windshield got covered in muddy water, the brand new wipers wiped it clean. I'll upload pics of the dirty Explorer later.

[ExplorerTom]

7/8/11
I haven't had an update in awhile, I just haven't done much to my Explorer lately.

Painted Front Grill

My front grill was not very pretty- I'm not sure if the grey paint on the center was either wearing thin and showing some black spots from the plastic or if it was lightly stained by something. Either way, I didn't like it. The truck bed liner spray I used on the bumper and side step trim worked and looks great.
I followed the Dirt/Celly removal guide:
http://www.explorerforum.com/forums/showthread.php?t=274316

Now on to the pictures!
http://www.mazdas247.com/members/Tom03es/Explorer/Painting%20grill%20(1)%20-%20no%20grill.JPG
http://www.mazdas247.com/members/Tom03es/Explorer/Painting%20grill%20(2)%20-%20unpainted.JPG
http://www.mazdas247.com/members/Tom03es/Explorer/Painting%20grill%20(3)%20-%20taped%20up.JPG
http://www.mazdas247.com/members/Tom03es/Explorer/Painting%20grill%20(4)%20-%20painted.JPG
http://www.mazdas247.com/members/Tom03es/Explorer/Painting%20grill%20(5)%20-%20done%20left%20iso.JPG
http://www.mazdas247.com/members/Tom03es/Explorer/Painting%20grill%20(6)%20-%20done%20right%20iso.JPG

I like it.

[ExplorerTom]

7/14/11
Third Brake Light LED Conversion

Like so many others, my third brake light was not working. I tried cleaning the plug up under the bumper with no improvement. Instead of going to the junkyard, spending roughly $35 and rolling the dice on a "new" ballast working just to have that fail on me at any time, I decided to go with the LED conversion route.

I ordered a strip of NFLS-x30[/URL (http://www.superbrightleds.com/cgi-bin/store/index.cgi?action=DispPage&Page2Disp=%2Flight_bars-flexible.html)] in red from [url]www.superbrightleds.com.

Removal of the brake light was fairly easy- drilling the rivets was a PITA. Once removed, I baked the light a little too long at too high of a temp (about 270 degrees). The lens was cloudy and bubbled up when I pulled it out of the oven- wasn't happy. But I got the light assembly apart. Here's the lens after a bunch of sanding (I was too pissed to take a picture right after it came out of the oven):
http://www.mazdas247.com/members/Tom03es/Explorer/rear%20brake%20light%20-%20sanded%20lens.JPG

I still had some of the 3M Headlight Restorer left over, so I was hoping I wasn't screwed quite yet.
Here's all the parts (old and new):
http://www.mazdas247.com/members/Tom03es/Explorer/rear%20brake%20light%20-%20parts.JPG

The lens cleaned up pretty well, I think.

To seal the light assy back up, I used some black RTV. Why? Just had some laying around. The smartest choice? Probably not. I left it clamped overnight to dry.
http://www.mazdas247.com/members/Tom03es/Explorer/rear%20brake%20light%20-%20clamped.JPG

Not wanting to follow in the footsteps of others that soldered the connector onto the wires BEFORE they fed the connector through the hole in the liftgate, I added some connectors.
http://www.mazdas247.com/members/Tom03es/Explorer/rear%20brake%20light%20-%20connector.JPG

Before I got too carried away, I wanted to make sure the wiring was good up to this point- I did put the multi-meter up to it before I removed everything, so I wasn't too worried. But I like to see bright, shiny progress.
http://www.mazdas247.com/members/Tom03es/Explorer/rear%20brake%20light%20-test.JPG

All done:
http://www.mazdas247.com/members/Tom03es/Explorer/rear%20brake%20light%20-%20done.JPG

[ExplorerTom]

8/8/2011
Road Trip 2011 is in the books!

The Explorer was loaded up pretty good- back cargo area full, stuff in the back seat, rooftop cargo box full and a hitch mount bike rack with 2 kids bikes.
Overall the Explorer did fine. It got tossed around in the wind a little- no surprise. Gas mileage wasn't exactly what I was hoping for. I had one tank at 18.x mpgs but most were 16.x- but I guess with the cargo box and the cruise set to 77-79 mph, it's not really surprising.

Not too many pics.

Here it is with the cargo box on top. I never got a pic with the bike rack on as well.
http://www.mazdas247.com/members/Tom03es/Explorer/cargo%20box.JPG
And the GPS:
http://www.mazdas247.com/members/Tom03es/Explorer/road%20trip%202011%20GPS.JPG

[ExplorerTom]

8/13/2011
Aux Transmission Cooler Install

So even though my Explorer had the OEM Aux transmission cooler, I figured it probably wasn't as good as an aftermarket cooler. With the towing I do up the mountains in the summer, too much cooling capacity can't be a bad thing.

I ordered a B&M aluminum transmission cooler (#70268[/URL ([URL]http://www.summitracing.com/parts/BMM-70268/)]) from Summit. It's roughly the same size as the OEM cooler.

Here's the OEM cooler installed:
http://www.mazdas247.com/members/Tom03es/Explorer/trans%20cooler%20install%20-%20OEM%20install.JPG

Removal of the OEM cooler is pretty easy- 3 fasteners:
http://www.mazdas247.com/members/Tom03es/Explorer/trans%20cooler%20install%20-%20OEM%20removed.JPG
Here are the 2 coolers side-by-side:
http://www.mazdas247.com/members/Tom03es/Explorer/trans%20cooler%20install%20-%20side%20by%20side.JPG

Installation of the B&M was pretty straight forward with the supplied brackets. You can pretty much do whatever you want. I used 2 fasteners that also secure top radiator close out panel (the black thing visible when you open the hood- has the hinged panels for the headlight access) and a lower fastener that's used for part of the air shroud. It's not straight- but neither is the truck.
http://www.mazdas247.com/members/Tom03es/Explorer/trans%20cooler%20install%20-%20B&M%20installed.JPG

I had to trim part of the upper air shroud on the RH side for it to fit properly.

I originally intended on only installing the B&M cooler and leaving it at that. But then the OEM cooler was sitting on my work bench giving me some sad puppy dog eyes. And the original mounting holes were still available....... So I hacked up what was the upper side support of the OEM cooler:
http://www.mazdas247.com/members/Tom03es/Explorer/trans%20cooler%20install%20-%20trimmed.JPG

So the OEM cooler is now installed upside-down from how it was originally installed.

The hoses were a little snug for my liking so I added some chafe protection by cutting a small length of hose and slitting it open. Then I used some black RTV as glue to hold it in place.
http://www.mazdas247.com/members/Tom03es/Explorer/trans%20cooler%20install%20-%20chafe%20protection.JPG

All-in-all, it works. No leaks. I don't have any temp data prior (or post) install to compare, but the extra cooler has to be helping.

[ExplorerTom]

8/21/2011
Went Camping this weekend up to Columbine Campground. It's just outside of an old gold mining town called Central City.

We drove past a 4 wheel drive trail as we were towing in. I didn't get any "action" shots really- by most people's standards, it was pretty tame 4 wheeling. Got the truck nice and dirty though.
http://www.mazdas247.com/members/Tom03es/Explorer/Columbine%20off%20roading.JPG
http://www.mazdas247.com/members/Tom03es/Explorer/Columbine%20off%20roading%20-%20muddy%20(2).JPG
http://www.mazdas247.com/members/Tom03es/Explorer/Columbine%20off%20roading%20-%20muddy%20(3).JPG

The new trans cooler certainly didn't hurt while towing. I hope to have the temp gauge hooked up soon.

[ExplorerTom]

9/30/2011
AUX Oil Filter Install

I've had this B&M remote oil filter kit laying around for a couple months now. I finally decided today was the day.

Started off by removing the front bumper and lower valance:
http://www.mazdas247.com/members/Tom03es/Explorer/oil%20filter%20install%20-%20bumper%20removed.JPG

This is the location I've scouted out. The filter has to be at an angle to clear the lower valance with minimal trimming:
http://www.mazdas247.com/members/Tom03es/Explorer/oil%20filter%20install%20-%20mounting%20location%202.JPG

I also installed a trans fluid temp gauge sender in a tee housing I pieced together at ACE Hardware:
http://www.mazdas247.com/members/Tom03es/Explorer/oil%20filter%20install%20-%20finished.JPG
http://www.mazdas247.com/members/Tom03es/Explorer/oil%20filter%20install%20-%20finished%202.JPG

Several people have suggested I remove the lower valance. I was never sold on the idea but I tried it out:
http://www.mazdas247.com/members/Tom03es/Explorer/oil%20filter%20install%20-%20no%20valance.JPG

I don't like it. Plus the oil filter hangs below the bumper.

But I'm a dumb-dumb and will be fixing it before I can drive it. I forgot to use teflon tape to seal the threads and it leaks.

[ExplorerTom]

10/2/2011
Painting front wiper arms

So the front wiper arms have seen better days. The leading edges were pretty sand blasted from the sand we use on the roads here in the winter. I got some Dupicolor Brake Caliper paint (with ceramic!) and repainted them black.

Before:
http://www.mazdas247.com/members/Tom03es/Explorer/wiper%20repainting%20-%20before.JPG
During:
http://www.mazdas247.com/members/Tom03es/Explorer/wiper%20repainting.JPG

I didn't get an installed pic yet- sorta got dark.

Anyway, they look a lot better but now the vented plastic under the wipers looks faded. Anyone know how to remove that? Does it just pop out or do I need to get to the underside of it?

[ExplorerTom]

12/24/2011

I don't really have much to update on, just share some pictures. It snowed roughly 12" the other day and it's been great driving around in it and busting down the piles of snow of the neighbors pile up in the street for me. Haven't got stuck- but I thought a couple times it was going to be close. This snow is very fluffy- very powdery. You can see below how it almost looks like a boat cutting through the water- and that picture was taken when stopped.

I went down to the storage lot where I keep my camper to shovel off the roof- and to give me an excuse to go driving through some untracked powder. I think I need some more ground clearance. The running boards are right around 12" from the ground.
http://www.mazdas247.com/members/Tom03es/Explorer/snow%20-%20storage%20lot.JPG

And this was after doing a bunch of driving down a gravel road that only one other vehicle had gone down and back. Plus more snow pile busting.
http://www.mazdas247.com/members/Tom03es/Explorer/snow%20-%20front%20end.JPG

The bad thing about doing all this- when I park it in the garage, all this snow melts and makes the garage floor a mess.

Oh, and the odometer just rolled 130,000 miles.

[ExplorerTom]

2/4/12

It snowed again. 22" this time.

I love this thing.

http://www.mazdas247.com/members/Tom03es/Explorer/snow%20plow.jpg

[ExplorerTom]

5/11/2012

New Gears!

In an effort to make my Explorer a better tow vehicle, I decided to upgrade the gears. I eventually want to also upgrade my tires to 32s or 33s and still have decent gearing in the end. I decided on 4.56 gears (stock was 3.55). I had them installed by Stang5lgt[/URL ([URL]http://www.explorerforum.com/forums/showthread.php?t=303902&highlight=merc)] who does tons of 8.8 regears- mostly for Jeep guys.

While he had the rear apart, he found that the carrier bearings were pitted and in need of replacement. So he tossed me the key to his Merc and I went to the parts store for new bearings. The Merc is cool. I'd love to see it in person off-road. Anyway, it was good to get some preventative maintenance done while we were upgrading.

The install took the better part of a day with a short break for lunch.

The end result is pretty cool. The throttle is VERY sensitive now. He told me to take it easy from a start for awhile until they break in a little. The speedometer is off now- probably close to 15 mph. I'll look into which speedo gear I need in the next few days.

Got a camping trip planned for next weekend so we'll see how it does.

[ExplorerTom]

5/23/2012

My speedometer was 25% off with the yellow 18 tooth gear that was in there. Last week, I installed red 21 tooth gear that I picked up from a local dealership. That was the biggest available in town (at least where I called). That got me about 9% off. Today I installed the 23 tooth speedometer gear. The speedo and the GPS are basically dead on now.

Took it camping last weekend. WOW! It tows great now. And that was with the 9% error which I believe was effecting shift points. Just driving around with the new gear, it feels even more responsive now. It's actually more fun to drive now.

Fuel economy doesn't seem too bad. Even with towing, the odometer is showing about 320 miles on the tank- which is approximately 9% high. But with towing approximately 213 actual miles, that's not bad. Not bad at all. On the tow to camping, I left the O/D off, even on the fairly flat interstate. On the way back, I left it on in spots. I don't have anything to compare it to with the old gears as I always left it off while towing, but it never seemed to want to shift out of O/D.

Trans fluid temp going back into the transmission reached about 130 degrees while climbing.

Stopped to pick up supplies while going up and the truck stinks. It's definitely coming out of the tailpipe. This was after lots of WOT while going up steep hills.

[ExplorerTom]

6/3/2012

4wheeling!

Today I went 4wheeling up above Central City. I mostly did Yankee (http://www.traildamage.com/trails/index.php?id=48) Hill, which I went on this winter with some people in the snow. This time of year the trail was completely clear with the only snow off in the shade of the trees here and there. As you can see from the trail link, it's not a difficult trail, but it was fairly rocky which made it pretty slow going in spots. The 30" tires make even small rocks seem big.

I didn't get much in the way of action shots since it was just me and my 6.5 year old daughter. She liked it a lot- even the really bouncy areas.
http://www.mazdas247.com/members/Tom03es/Explorer/Yankee%20to%20Cumberland%20(4)%20-%20first%20rest.JPG

And then I connected with Cumberland (http://www.traildamage.com/trails/index.php?id=49) Gulch on my way back to the pavement.

This is about the only "action" shots I got:
http://www.mazdas247.com/members/Tom03es/Explorer/Yankee%20to%20Cumberland%20(13)%20-%20turn.JPG
http://www.mazdas247.com/members/Tom03es/Explorer/Yankee%20to%20Cumberland%20(14)%20-%20pig%20parking.JPG

The gears worked great- especially coming down. 4 LOW and 1st gear had all sorts of engine braking- didn't need to use the brake at all. The transmission temp got up to about 150 degrees (going back into the trans after the 2 aux coolers) while going up slowly. I also seemed to notice a lot of engine heat- the gauge was fine I could just feel lots of heat (windows down and air temp about 70 degrees). Hit a couple rocks here and there that weren't intentional. The side steps on the driver's side took a rock and may have bent it slightly- rock sliders are being pursued.

All in all it was a great time. Can't wait to get out on the trails again!

[ExplorerTom]

7/26/2012
Body Lift Complete!

Well, it took the better part of a week due to the pace that I worked and because I had to order new mounts for the front and new bolts after I broke one that I was planning on re-using. All-in-all, it was an easy install. I bought the body lift blocks from Zone Off-Road and the bolts from Fastenal. The resulting stance is great. I use to be able to see over the roof- not anymore! And the step in/out feels more like how a truck should be.

Next up is an RLC bumper to do something about that horrible gap up front.

Here it is almost 2 years ago just after I got the new BFGs:
http://i642.photobucket.com/albums/uu143/TJUrbanek/Explorer/newBFGs3.jpg
And here it is today:
http://i642.photobucket.com/albums/uu143/TJUrbanek/Explorer/bodyliftcomplete2.jpg

I'm not too worried about the rear bumper. I was able to heat up that plastic closeout piece and flatten it out. Other than the trim not lining up on the side, looks good to me.
http://i642.photobucket.com/albums/uu143/TJUrbanek/Explorer/bodyliftcomplete.jpg

The front though, needs a new bumper to sit higher:
http://i642.photobucket.com/albums/uu143/TJUrbanek/Explorer/bodyliftcomplete3.jpg

[ExplorerTom]

And my photobucket account has reached it's bandwidth limit.

I'll continue later.

[alexb]

Fun read. Thanks for sharing. :)