93 Ranger Daily 2.3 Eco Build

[Tinstar36]

I will start with the how I came in to possession of this fine American machine. I was at work minding my own when the old man called and sent me some pictures of 2 93 rangers on his job site and asked what i thought they where worth as I had just finished getting my 96 2wd 3.0L Ranger that I picked up out of a field to save fuel and miles on my 19 F350 tow rig, Well after looking at them I was in the $1000 range and He said thanks. That weekend I went by the shop only to see the two 93 rangers setting there so I looked them over. One was just a parts truck but the other was in great shape other then then the drivers side was crashed. I ask what he was going to do with them. He didnt have a good idea yet so I told him my plan that I had and got the green light.

The Plan:

Ok so the main use is for a all season Daily Driver that has good road manners, 25mpg or better combined, Good a some basic offroading, and is semi fast/fun to drive.
How to make this happen?
Tight up the suspension with poly bushings and keep the ride height as low as possible. maybe a heavy sway bar up front
31x10x15 Tires for traction and the ability to air down but not so big that they are expensive or kill mpgs.
Lockers to make up for the lack of flex and a winch.
manual hubs to help with mpgs
Tan paint to make it look good.
at least 300 hp and the ability to tow 5000 lbs.
so the only ford motors I know of that will fit, have 300hp, and get 25+ mpgs is a Eco boost.
The most reliable and cost effective one is a 2.3l Eco out of the mustang or new ranger.
Want the ten speed auto to help with the mpg, and towing.
That is the main plan and use of the build. may go do some mountain passes with the family but it would do that easy with the current plan so theres no need to add any thing for that.


First step is to rebuild the ranger so it is a good hoist for the new drivetrain as I save up for it. (10k)
I started on what I feel is one of the most focal parts The TTB Dana 35.

 

[Tinstar36]

Pulled a part the parts truck and sold some of the interior parts I did not need and made a quick trailer out of it so it was still easy to move around if in needed to roll it back in the shop. I needed the hood, driver side fender, radius rod crossmember, bumper, and headlights for the repairs

 

[Tinstar36]

Got the 93 on the lift and started the tear down. Dropped the axle out and replaced the broken steering box with the one off the parts truck. ordered a locker and seals for the dana 35 as well as poly bushings for the axle pivot and radius rods.

 

[Tinstar36]

Parts started pouring in so it started to feel like it was moving along. Still dismantling things at this point. To convert auto to manual hubs you will need a kit on top of buying the hubs so that is something to keep in mind. Locker number is pictures as well.

 

[Tinstar36]

Had to buy a thinner shim set for the locker to have the right tolerance the .035 stock thrust washers where to thick and it wouldn't let the locker fit. But after a week to have thinner washers sent to me from Torq Masters it is in and checked out good.

 

[Projectjunkie]

 

[Pony_Driver]

LIKE

 

[Jbevs]

LIKE

This

 

[Tinstar36]

Work at it and got some Paint on the Axle and the new bushings/seals in. I had to order some u joint straps for the front diff some one got happy hands and over tighten the small bolts so that they broke as I took them out. Nothing a welder and socket couldn't fix though.

 

[Tinstar36]

My spindles are damaged from the race spinning. And I can not find new one for under $375 (with long lead times) each so I dotted them and that work fine on the drivers side but the passenger side is still given me some issue that I hope some copper wire and bearing retainer Loctite will fix it. I will try that today before work. I hope to find some better spindles at a pull a part or something? If it gets to involved I will get some Jk axles, though I don't want the extra weight at least I will have part available to me. Again this is a Daily that will get 15k miles a year plus so being able to repair it easily is part of the over all goal.

 

[arse_sidewards]

Good fuckin luck.

I think you're gonna come up short in the MPG department and power is the least of these trucks problems when you put 5k behind them.

31s and lockers is a smart choice.

 

[arse_sidewards]

My spindles are damaged from the race spinning. And I can not find new one for under $375 (with long lead times) each so I dotted them and that work fine on the drivers side but the passenger side is still given me some issue that I hope some copper wire and bearing retainer Loctite will fix it. I will try that today before work. I hope to find some better spindles at a pull a part or something? If it gets to involved I will get some Jk axles, though I don't want the extra weight at least I will have part available to me. Again this is a Daily that will get 15k miles a year plus so being able to repair it easily is part of the over all goal.

D44 knuckle/spindle swap and re-drill rear.

 

[Tinstar36]

And now we are to where I left off yesterday. Had a bad u joint on the passenger side. It had to be shaved down to fit in the hole. the spring is the common C clip eliminator do to not being able to put it in with the locker. I used a welding rod as my ring and tacked it around to hold the spring. The bushing are for the rear of the truck as soon as I can wrap up the front axle.

 

[Tinstar36]

D44 knuckle/spindle swap and re-drill rear.

Dont really want to change the lug pattern do to having a good supply of rims But what D44 knuckles (vehicle and year model) fit my D35 ttb housing?

 

[Tinstar36]

Good fuckin luck.

I think you're gonna come up short in the MPG department and power is the least of these trucks problems when you put 5k behind them.

31s and lockers is a smart choice.

Thank you it never hurts on projects like this to have all the luck one can.

The New Ranger runs the 2.3 eco and 10speed and mostly gets in the 20s on mpg. And it is rated to tow 7500. All I have is a mini ex and my RZR. here's my 96 doing a ok job of it. Yes this is only about 3000 lbs. but this truck is only a 3.0l with a bad auto trans. Brakes where just fine and it handled ok but it needs bushings and shocks.

 

[Tinstar36]

Dana 44 Knuckle Swap On To Dana 35 - The Ranger Station

Sweet I found it Thanks
I just may do this to save some weight and the bigger brakes will help. Will have to see how this pans out when put up to the JK axles.

 

[arse_sidewards]

Dont really want to change the lug pattern do to having a good supply of rims But what D44 knuckles (vehicle and year model) fit my D35 ttb housing?

Any TTB F150 works. It's a common swap.

Dana 44 Knuckle Swap On To Dana 35 - The Ranger Station

Written By Todd (Forum Member) Part numbers for upper and lower Dana 44 ball joints. Also a set of off set 44 alignment cams are needed. First the proper ream must be obtained to re taper the lower ball … Continued

www.therangerstation.com

 

[Tinstar36]

Had a good days work on the ranger. Got some Better shocks on and converted the drums to Mustang Disc brakes ( I will post the link at the bottom). It wasn't as bad as rebuilding the drums so it is a double win if there is such a thing. I cut a little more off the bracket to save weight and clean up the look. I also scored a super light aluminum diff cover off the mustang axle to replace the surprisingly heavy plastic one. Ordered some rotors and pads to start out new as well as axle seals so I wont need to mess with the rear axle until I am ready to put the eco boost in and then i will pull the axle and paint it tan like the rest.

On a different note I will be staying with the Dana 35 knuckles at least for now to save weight, money, and time as I found some new spindles for a fair price.

Ford Ranger / Bronco II Rear Disc Brake Conversion - The Ranger Station

By: DangerRanger01 This modification only works on the Ford 7.5-inch and 28-spline 8.8-inch axles. IT DOES NOT work on the: 2002 FX4 Off Road 2003~2007 FX4 Level II (but NOT FX4 Off Road) 2008~2009 FX4 Off Road (only when equipped … Continued

www.therangerstation.com

 

[Tinstar36]

Well work is slowing back down now and I have made some progress on the brake lines and added new shocks. Making a custom bracket for the E brakes to weld to the axle more on that later when its done.

 

[Tinstar36]

With the brakes done i was not happy with them not being hub centric so plasma tabled out some 1/4 thick rings and drove them on and now it is

 

[Tinstar36]

And now its time to put the front back together and get ready for a few shake down runs.

 

[Tinstar36]

Truck is up and running now. Gets about 18mpg and the rear brakes are more then enough to lock up the rear with a trailer on. May need a brake reg. To even that out. Hauled a 3k house trailer with lawn mower on a 60 mile round trip. It was good other then power and needed a trailer brake controller. Drive like you have a trailer on and it did well. It was not the set and forget like it would have been in my F350 but it gets 13 mpg unloaded where I got 14 mpg with the trailer on the ranger.
Will have some more pictures and build updates when I can recover them from my phone. Lot has happened in the last few months and I will have to say this year has been the worst in my life, but hey new experiences and I am still on good side of things over all. Cant complain other then to explain the slow progress.
The ranger has been the best daily I have owned. Its tuff, 4x4 and cheap to keep.

 

[gozuki]

Did I miss the eco swap?

 

[Tinstar36]

Did I miss the eco swap?

No, Sir it is still coming

Wife was in a roll over and family member passed away. Its running on the stock 4.0 right now hoping if economy stays good i can get the 2.3l in hand next year. Hope to paint the truck this year but its been busy with the above events.

 

[Projectjunkie]

I'm sorry you've had to deal with that