2013-06-28

repowering a Ford Explorer again after a long time

Been replacing the engine and gearbox of a '97 Ford Explorer in order to run on diesel. Last time I did it was in '07 with an older model. This time a Kia J2 engine was chosen, out of a Kia K2700 alongside the starter and powe steering pump mounting brackets. The alternator came out of a Toyota Hiace. Initial plans were to retain the automatic gearbox, but due to electronic controls input required for it to work properly it was soon pulled out of the project and been replaced by a 4-speed manual transmission which had been laying around the garage of the house of the rig's owner, from a Chevrolet Ranger 2500, which was probably the source for the brake master-cylinder too, since the OEM vacuum-assisted from the Explorer wouldn't receive any vacuum input from the diesel engine. A different pedal assembly to accomodate the clutch was still easier than messing with the electronics of the automatic transmission, and the non-assisted master-cylinder is still lighter than the OEM, and doesn't either decrease reliability of the brakes or take power from the engine as an auxiliary vacuum pump would. The only problem was the anti-lock feature, which couldn't work anymore without the electronic input, but this problem was solved replacing all those sensors with some hydraulic pressure relief valves I bought in China. Positively, being the RHD version of the Explorer which was aimed at Australia, United Kingdom and South Africa, with a central console holding a parking brake lever and the shifter instead of using the pedal-actuated parking brake and steering-mounted shifter from the LHD, it was easier to assemble the manual shifter. It runs, but the instrument cluster needs to be converted for mechanical input, and a new assembly is required for the aircon compressor.

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