$350 Ford Explorer
 

I recently bought a 1994 Ford Explorer for my son. It isn't planned to be anything more than a grocery getter. But it is a small gift from me for his 21st brithday, and a bit of an early wedding gift (he is getting married in August) It was an inexpensive purchase because, it has a dead transmission. I am rebuilding it myself.

So my question, while I still have the thing apart. WHAT sort of modifications can I do to an automatic (it is a Ford A4LD) that MIGHT help it get better mileage. I have purchased some parts in the better interest of durability and HD usage. I still have less than the purchase price in the trans and will probably have it buttoned up this weekend to put back in the truck. Any FE ideas now while its open would be good.

And when this transmission goes out (if it goes out), we will decide what to do with the truck. It currently has 194,000 miles on it, but the motor is tight and has great compression across all cylinders. No smoke and it sat for over an hour running and didn't overheat. We almost put in a 5 speed manual instead of rebuilding what we have. That is a viable option for later. But likely, with the mileage on it, it will get recycled when the trans dies next...

YES, I know it isn't a very fuel efficient rig. On the other hand, it goes to my son with no strings attached, no car payments and its old enough that insurance won't be a big issue for him and his soon to be bride. It is large enough to be a safe vehicle if they start a family right away too. And with functioning 4x4, it wil be a safe winter vehicle. And the boy knows how to drive for FE. Who do you think has been getting such good numbers from my Neon?

That is a great gift from you to get them started. Hopefully they will appreciate it.

For the A4LD you might try to find a controller that will allow adjustment of the shift points. An earlier shift may see some gains. Also use a good synthetic (I like Royal Purple) trans fluid. While you're at it, change the diff oil to synth as well.

This is just wrong. Large, high-centered vehicles are not safe. See for instance here: Are S.U.V.’s More Dangerous Than Minivans? - Wheels Blog - NYTimes.com Nor is 4WD safer in winter - ever watch some flatlander in their shiny new 4WD hit the brakes on a snowy road, and do 360s until they're out of sight?.

He already bought it. Berating his decision is not productive.

Also I have driven supposedly "dangerous" SUV's such as a ford bronco2, a mitsubishi montero, and two isuzu troopers - more than a combined million miles in every possible kind of condition in North America and not once did any of them roll over or even put me in danger. Maybe luck? Much more likely is that I keep the nut behind the wheel tight and don't drive them the same way I drive a sports car. 'tis a poor musician who blames the instrument.

Zjrog - as you probably are already aware, the A4LD is a failure prone transmission. To prolong its life, install an aftermarket transmission cooler and an auxilliary transmission filter. - plumb the cooling lines from the transmission to the filter (fluid still hot from trans so it goes through easy), then to aux cooler (so it looses a lot of heat) then to in-radiator cooler (so it doesn't get TOO cool, and so it warms up faster at startup) and then back to trans.

Increasing line pressure to shorten shift duration should help fuel efficiency a bit, with the reduced overlap.

I can't say enough good about synthetic ATF.. mmmmmmm damn i wish it was less expensive.

I wouldn't use the word "berating". Causing him to question his apparent belief that the mere size & 4WD will provide safety IS productive, if it causes appropriate changes in driving behavior - in your words, to tighten the nut holding the wheel. We've probably all seen too many drivers who think SUV translates to invulnerability.

I can see that, you're right. :thumbup:

I was already planning to use a synthetic, but I want to wait until the first filter change after the rebuild. I'm also going to use synth in the transfer case and the differentials. Just like I do in my Jeep and in my daughter's Jeep. I'll look for a shift controller and see if its something that will help, I did look at different weights on the governor to change the OD kick in point. We will change that when I do a filter/fluid change, because I want to see where it shifts to begin with. Remember, I brought this truck home without being able to drive it. I know the brakes work, as they hauled my F150 to stop from 30 MPH (F150 was towing it home). I bought heavier duty parts where I could to prevent further issues.

http://i178.photobucket.com/albums/w...Sploder002.jpg
Not bad looking for a $350 truck... And the interior is MUCH nicer!

Now, the OTHER comments... Simply wow. Self righteous much? If the Explorer is driven in a reasonable manner, it can be as safe as anything else on the road. My almost 21 year old son is very familiar with driving FWD and 4WD in inclement weather. I'd really like to think I've done a good job teaching my adult kids how to drive so they don't NEED 4x4, but with it available, they have an advantage. I'll tell you what I've seen over the years as an accident scene photographer. Fewer fatalities in larger vehicles. This Explorer isn't that tall. Its not a Hummer H2 or whatever you are truly afraid of. If I didn't think my son was responsible enough to drive something like an Explorer, I wouldn't have bought it. Yes, you really rubbed me the wrong way. I'm going to guess you've never driven a 4x4 in bad weather, or had the pleasure of exploring trails far from a paved road. If you'll go back to the original post you might notice I'm trying to resurrect an inexpensive vehicle (a form of ECOnomy) and see where I can MOD it for possible improved FE. Does that not fit the ECOMODDER sensibility? And as a gift to my son, and his bride to be... Some people can find fault with anything. I ADMITTED it isn't the most fuel efficient vehicle out there... Care to comment on the lightly used furniture I saved from a landfill for them?

My "apparent" belief is borne of actual real life experience. And my "apparent" belief doesn't include thinking that 4x4 is the answer to everything. Beyond that, I had written more but I choose not to include it as I may be suspended. Please take a moment to re-evaluate your stereotyped thinking... Not everyone with an SUV is evil.

THANKS!!! And yes, they do appreciate it. And if my son didn't have classes and tests, he'd be doing this work, not me!!!

Nice truck! And nice recycle!

It gets okay mileage for a full-blown truck. And since you probably get a lot of snow in the winters, it will be nice to have then.

Didn't get so much snow this winter... But there is always the potential. Old timers around here point back to a time in the 80s when there was never less than 4' of snow in their backyards...

Thanks. It might be overkill for its intended purposes, but the price was just too good to let it go.

I have this project complete now.

In the teardown of the trans, I found the overdrive planetary section had broken, and the forward clutch friction plates were all as smooth the steels between them. No metal chunks in the pan (well, a couple slivers from the the OD section that broke), beyond the normal wear and tear "fuzzy" magnet. The forward clutch failed because of a cut in the piston seal. Was it from the OD section failure? I do not know. I replaced the OD planetary, bands, torque converter (a HD replacement as there will be some towing with it) and a soft rebuild kit with steel and friction plates. THe valve body was cleaned thoroughly. and everything put back together. A couple of thrust washers were replaced with torrington bearings. Don't know if that will help FE or not.

Everything got put on hold when my wife fell ill and was hosptialized for a week. 4 days in the ICU with the first day the docs were not expecting more than a couple hours. She pulled through and is doing better. On O2 for a while and earned herself a handicap placard for the rearview mirror. She is doing better and improving daily though!

Finally got the trans back in the truck last week, and this past weekend we rolled it out of the garage and took it for a drive. I decided it was going to work, or I was going to kill it. It just seemed like it was holding gears against each other. In neutral, it would roll forward, but not backwards. When it shifted it felt like the brakes were grabbing, then it would take off. So I did the most illogical thing. I took it on the highway and floored it. Must have been an airblock of sorts, somewhere, because it sounded like high pressure air escaping (which made me think I killed it...). But then, it shifted smooth, no more feeling like the brakes were applied. In neutral, it rolled forwards and backwards. Reverse worked. And NO LEAKS!!!

So, we drove it around town for about an hour and just keeps getting better. My son and his fiance are happy, and can barely wait for me to release it to him. I'm happy it works, and now I can move forward on other projects (like the solid axle swap into the front of my Ranger)...

For a truck with 190,000 miles under it, it sure drives nice. Starts easily, doesn't smoke or make any odd noises. Doesn't have any strange rattles or other noises when going over bumps (interior plastic thats 15 years old does make some, but I'm not worried about that). Tracks straight with hands off the wheel. Brakes nice and strong but smooth. And it runs quietly. Now to put some new tires on it and give to my son. THe boy is setting a goal of 20 MPG with it. I'll let you know if he gets there.

I'm no longer afraid of automatic transmissions, but I'm not real sure I "look forward" to doing it again anytime too soon.

Glad to hear your wife is feeling much better, my best wishes go out to you both. Keep an eye on the front suspension and steering in those Explorers as they had a lot of failure/misalignment issues similar to the Rangers. Heh, I hear you on not looking forward to working on an auto trans rebuild or repair.
Good luck to your son and fiance, to your life, and the hopeful longevity of that Ford product.

(yeah, not a big ford fan, but there is always going to be the ongoing debate of ford vs chevy) :thumbup:

The Ford Twin Traction Beam arrangement is pretty reliable and rides nice as long as the truck is maintained and not abused. Gives some of the best of the independent suspesnion and some of the best of a solid axle. Still going to have its alignment checked, but the fact it has 190,000+ miles and it still rides nice says something.

Now my Ranger is another story, it has been abised which is why I'm throwing a solid axle under it...

Thanks for the well wishes. Always appreciated.

And the Ford vs Chevy debate rages on, Chevy, like a rock, heavy and immovable!!!

So I got the Explorer on the street, got it safetied and tagged. Put about 400 miles on it during the week. As it sits, its getting a measely 15 combined. My tech friend thinks the catalytic is dead. It does have 191,000 miles under it and it looks original. It will be replaced.

My son picked it up today, drove it to see some friends (after being overseas for the lat two years), and then took it back to where he lives, Over 500 miles, and 16MPG. At least, it is rated average mileage. Not bad for a high mileage SUV. No plans to lift it, keeping it at original stock ride height. Since it doesn't leak, its next oil change will be with synthetic (on my nickel), and I already changed front and rear differentials with synthetic lubes and the transfer case too. After its got about 5,000 miles on the trans my son might swap the ATF fluid for synthetics, But it will get afilter change and some fluid swapped anyway.

I know an SUV isn't a popular vehicle here, but my son and his fiancee are pleased with the gift. I gave them both keys and the title. They are good kids, and the truck is a positive for them. Someplace for him to lock up and carry his construction tools, a 4x4 for camping, and bad weather, and enough HP to tow my tent trailer when they want it. We are hoping her parents pass the Subaru she currently drives over to them too. I've got some furniture for them as well for their future. Meantime, they are very happy, and as a parent, I'm very pleased.

http://i178.photobucket.com/albums/w...0090512004.jpg

A parent does what a parent can. This project is done. Next, the 4 cylinder 4x4 Ranger that I was getting 28MPG with a couple years ago before I took it off the street for safety issues.

I'm sorry, but 16 isn't "not bad". Full size V8 4x4 pickups get that or better, and the Exploder is quite a bit smaller than them.

Ya needs ta raise the bar!

I know 16 isn't that great for todays trucks. It IS a 15 year old, high mileage rig, and it did sit for 2 years. As mentioned, the current goal is 20. My tech friend thinks changing the cat ought to get us there. Work continues. I've run Lucas conditioner through a tank to clean and lube injectors (one was ticking and it isn't now). More will be done. The roof bars are off, and we will replace the front valance with one that isn't cutout for foglights. My son is pretty good about wringing mileage from cars. So for its first drive in years, that isn't a bad way to start, delivering rated mileage. We will work at getting it improved.

No leaks, starts easily, idles well, no smoke out the exhaust at idle or off throttle. I didn't run a compression test yet, but imagine that it has even numbers across the cylinders. Little to no blowby, no oil in the intake. We will run Seafoam a couple times to make sure things are clean inside.

Bar is raised... 20 is a goal. Higher if he gets 20 with a replacement catalytic.

Thing about those newer trucks and SUVs, they come with a high price tag and monthly payments and healthy insurance bills. For a young couple, starting out and making their way in the world, that is a lot to pay for. So even if the truck isn't a 30 MPG miser, they will still be ahead with NO big insurance bill or car payment ,as a nice tidy figure, I reckon this could save them over $500 a month at least. As a young couple still in college, thats a lot of money saved. Not to mention that I'm out less than $800 plus my time to get them rolling towards their future. Eco isn't always about mileage (but its nice when that is gained as well).

My full size '94 V8 4x4 truck gets better than 16... last tank was 22... as you can see, it ain't any newer than the Exploder. BTW, it's parked unless something big needs to be hauled. I think that is the role of the large truck in this world. 20... well in this day and age, that's a pretty low bar for a dd unless you are hauling great gobs of stuff.

You sayin you couldn't find a nice GM sedan with the 3800 for cheap? Lotsa room, lotsa comfort, lotsa SAFETY SCHMAFETY, and up to 30 mpg to boot. Did you even look for something like that? Ya know, buying a vehicle cuz this or that "might" happen in the future ie carting a brood around is PRECISELY the reason we have millions of doofs in this country commuting in full-size 4x4s... they think that maybe, someday, perhaps, there's a chance that, oh i don't know but maybe, ya think? possibly... they'll need that capability someday. In the meantime they are quite happy to rack up hundreds of thousands of miles without using that capability in the least. It's kinda like bringing a Sherman tank to a knife fight.

I agree with you re: used cars. Nothing saves more money than keeping an old car on the road vs getting a new one. That 28 mpg Ranger- now that's more like it.

Two of the guys I carpool with drive 3800 GMs, ones a Buick Regal the other an Exciting Pontiac Grand Prix... Barely enough room in the back for me, and my head rubs the roof. But they aren't bad on fuel I'll admit.

10 years ago I made fun of the SUV crowd that HAD to have 4x4 but never used it. I took my old minivan offroad to prove that you didn't NEED 4x4 to get most places. Amazing how defensive some folks got, but then missed the point entirely. On the other hand, we frequently go now where the old minivan couldn't dream of going. So our 4x4s do get a workout. I hope the Explorer can keep up. And my daughter's 1990 Cherokee 4x4 is a nearly stripped model, she has gotten a best of 23MPG with it. Again, a vehicle that didn't cost much to buy, has no monthly payments and cheap cheap for me to insure. Capabilities are used, not squandered.

As for the Ranger. Its a 1990 4x4 with the 2.3 and a 5 speed. It has a 6" lift and was on 31" tires. 75MPH is doable, but not comfortable. No need to rush in this truck. Replacing the original front suspension with a solid live axle so I can keep alignments longer and not tear up front tires as quickly. Also moving to 33" tires because it will be easier to get over obstacles. This is more trail rig than highway machine. It will still get better mileage than my Jeep, but we'll see how it does when it returns to the street in the next few weeks.

Yes, keeping an older vehicle on the road can be cheaper, but only if you do the work yourself. And you have to know when it is a lost cause as well. Which is how I sold my wife on the idea of buying my Neon brand new a few years ago.

too bad a lot of people are missing the point here. some people like to travel (in a vehicle) beyond pavement and graded gravel roads. oh well, some get it, some never will.

an (older) explorer is not a "big suv." its a smaller, street-friendly vehicle thats very capable off-highway in stock form. it sits up tall enough to help see around the mammoth garbage thats on the street today.

keep in mind (older) explorers are every bit as capable as a 1/2 ton truck. lots of parts are the same. trust me, i could make a long list.

also, those 4 doors are perfect for camping. lay down those back seats and you don't even need a tent.

my parents had a '94 explorer 2wd. lasted 298,000 miles before blowing a head gasket in 2000. sold it to a guy that changed it out and is still driving it.

i agree that the cats probably need to be replaced. full fluid change too, as i am willing to bet the axle fluids have never been changed.



and i would like to say that what you did for your kid was very admirable :thumbup: it sounds like this rig will fit his needs very well. everyone has to start somewhere, and you are giving them a great one :thumbup:

Thanks Tony. I tackled something I've never done (never did find out if there was something I could for FE with the trans...). We are active in Land Use issues locally to maintain what limited access we have as it is. I've slept in the back of my own Jeep, but the Explorer will be a nicer place to snooze. And as mentioned, the kids do appreciate the intent as well as the gift.

really, the only thing you can do with an a4ld is take really good care of it. 5-speed swap is still the best(would take you over 20 mpg easy), but i understand that may not be in the cards.

:thumbup::thumbup: for being involved in land issues. education and involvement are key to separating responsible 'wheelers from the drunken yahoo's


oh yeah, and :thumbup::thumbup: for taking apart and auto trans. thats one job i wont tackle

Ha! It wasn't that hard. Really. Good documentation (I really did RTFM), and keeping track of parts laid out is key. Keep things clean as you go and plenty of vaseline during reassembly.

A 5 speed swap is never out of the question. If the truck is still running well when this trans dies again, we'll look at it. I already turned one down for dirt cheap. I might have to get another whole truck for all the parts too...

Going on a trail cleanup this Saturday in fact. And my club has adopted a trail up in the mountains. We've built fencing and signs and worked with the Forest Service. But it'll be late June before we can get there. Gotta wait for the snow to melt enough to drive up there. Very few stock 4x4s make it to the lake up there... Education is key, just like Ecomodding...

Hey, just saw your thread, I made a thread detailing my somewhat successful efforts to get good FE out of an Explorer I drive at work, you can see it here:

http://ecomodder.com/forum/showthrea...-suv-7975.html

I read that thread and thought you did a good job. I'd love to swap a 5 speed auto in, but don't want the extra electronics. And I am looking for a 5 speed and associated parts for this truck if the A4LD dies. But, its not my rig, my son has it and that was how I expected it to be. He really is good at pulling mileage.

I might mention in a 4 hour time frame, our trail cleanup filled a large rolloff dumpster. We removed lots of trash, tires, an truck bed trailer, a lumber rack (?), and one burnt out car. Of course, that was on a Saturday before the holiday weekend was over. What WAS nice to see, ATV users that weren't part of the cleanup picking things up as they found them. We spoke with lots of users of the recreation area and many joined in with no hesitation. When I picked up a large chunk of plywood, we found a small rattlesnake. We had a couple small children with us and we took the opportunity to teach a little respect for the critters. Pushed a little dirt at him to get him rattling for the kids, but then he turned away and we let him be. He was a cute little guy though.

And, the cats were plugged in the Explorer. When we knocked the guts out, the truck became a real power house. I am waiting to hear about mileage results though. Should hear about that tomorrow. I'm hoping to hear better than 19... 20 would be better.

Edit... I will add that I have ordered a replacement cat setup for the truck...

Just as a note, the truck finally broke into the 19s. This is averaged of course, and did include some 4 wheeling... But now that my son is comfortable with the truck he is using the cruise control more. He and I know it can do better.

What mpg he get now?

I sold my 01 F250 5.4L It was get 16 mpg in city but no room for 5 people

I bought 94 Ford Explorer with 4.0L plus automatic.


I have question did you put bigger cooler on that? My transmission cooler is extreme hot after drive hard to clean excess carbon in engine due bad MAF sensor.



What tires size he have on? I notice that my tires was 235/75/15 it was optinal tires size on explorer that first owner custom order.

No real updates. I put a set of 31s I had laying around on it. But it needed new tires last year so he put 235s back on it. The cooler that was on the truck is the same size as one I pulled off a F250. I haven't checked its temp though. Since my son is using my Neon for highway driving, he hasn't pulled MPGs off the Ex for a while. HE moved last summer after losing his job and is back in college so the Ex is around town driven. We will likely put a 5 speed manual in it this summer.

I had my knee replaced 11 weeks ago, so I am way behind on so many projects...

Sorry to hear that, hope the recovery is going well.

In true DIY fashion you should save the old one and rebuild it. :D

Ah I understand. We hope your knee get better.


My explorer got 23-25 mpg at 60 mph that was very diffident to archive that.

Going to close this thread out. Its been over three years since my knee replacement. Its fantastic! Don't fear replacement, but make sure you get a good physical therapist, and do EVERYTHING needed. I have 140+ range of motion, and I use it all every day.

I'm still behind on projects. But this one is complete. My son and I stripped this vehicle down and we used EVERYTHING in his 1990 Ranger. The Ranger previously had been a yard ornament for too long and has been a daily driver now for 18 months. Now that he is employed, the Ranger will become a desert toy.

This project is complete and finished, it was a great bit of education for myself. the body actually lives on as it was used to repair a rolled Explorer.

it was a pleasure to read your road traveled with the "Explorer". since life is over for it, now it can be called "Explored".
i was really surprised to read some of the comments that were made. i figured there would be a lot more support for the gestures that were made towards a young couple starting a life. hope they are still together. if the same would have been made towards me 32 years ago, i know the adjustment would have been easier and would have made a difference to me. good job!

Explored. I like that. And it does close that chapter. My wife and I both already had cars when we were married nearly 31 years ago, she had paid hers off, I was making payments. But a free, no-strings vehicle would have been very helpful. What I hadn't mentioned, and re-read the thread to see, the boy didn't marry the original girl, she flaked and ran away. But a year later, he married another girl. Now he is graduated and working in his field ( a rarity for college grads these days!), they bought a car, returning my Neon to me, and are looking at a vehicle when they pay the car off next year to replace the STILL running and driving fine Ranger aka, Explorer in Disguise. After nearly 40,000 miles, that transmission is still shifting good, though it needs to warm up a bit when really cold now.