OK so i did some extra work and got a bunch of the Ranger/Starter harness labeled up so i can figure out where to splice (and others)
12 Pin Connector
12 Pin Connector Pinout
2. Red / Yellow - AC Condensor Switch
3. Black - AC Compressor
5. Black / White - AC Condensor Switch
6. Grey / White - AC Compressor
9. Yellow / Blue - Starter
11. Green / Red - Alternator
As shown in the picture, your V6 Ranger alternator has the external white/black that loops out of the alternator from the stator and back in to the regulator. The Ex V8 alternator that I used must have the equivalent of the WH/BK wire routed internally, so I just cut that unneeded wire off of the Ranger harness connector. It plugged right in and works fine.
Heres the next project. Starter/ Charging harness and how its integrated.
hope to have them labeled soon.
Ok, looks like your starter harness is from a 96-97. Anyways, what i did with it is kept the power wire to the starter, which i merged with the ranger's main power wire at the battery connection, The main ground, which i also merged with the ranger's main ground wire. Also, the starter signal wire, #2 on your top pic, merges at the battery tray with the yellow/blue (believe was yellow/white in my truck, but whatever) wire from the 12 pin connecter. The extraneous connectors, mainly #6 solenoid connection, can be traced back and deleted.
The second harness you show is the explorer charging harness, and i discarded that completely. It has the two alt control wires, the ac condenser, the ac compressor, and the main alt charging wire.
EDIT, on second thought, i believe the explorer ac condenser plug is part of its headlight harness, not on this cable. Irrelevant though, below procedure still works.
I used the ranger main charging wire, (i believe its integrated in the ranger main battery cable, but its been awhile), and the ranger's ac condenser and compressor plugs down harness from the 12 pin plug. I had to extend one or both, but they plugged right in.
That leaves just the small alternator wires. In mine, i made a custom harness using the ranger plug (as i have the ranger alt still, but i believe the plug is the same) and a yellow and a green wire. In my truck, both were integrated into the main chassis plug up by the computer, but it may be different in yours judging by the green wire in the 12 pin (i didnt have that).
So other than changes to the custom alternator harness, that should give you a good start.
5.0 Explorer positive battery cables to starter positive and the Distribution Box
5.0 Explorer negative battery cable grounded to front of engine block and radiator core support
Ranger alternator cable and wires
IIRC, I used most of the original Ranger subharness from the 12-pin on the DS inner fender to the AC compressor clutch, AC high pressure cutout switch and the LG/RD charge light wire and merged the Ranger YE/BU to the Ex YE/BU starter solenoid wire. Then bundled the whole mess into one harness.
Two things bolt down at the front of the Distribution Box:
The original double bolt terminal from the factory Ranger cables is mounted in its original location on both of the two lugs.
The terminal on the end of the positive battery cable from the 5.0 Ex. mounts on one of the lugs.
It was just a convenient place that avoided splicing or adding a dedicated junction terminal lug somewhere else. A little trimming was necessary on the Explorer terminal to make it all fit together.
ok so run the starter wire from the ranger harness directly from the starter to the double lug? or is that one of the wires that gets tied into those fuseable links?
OK, I've been digging into my harness to see how I actually did this three years ago.
First correction: I used the Explorer positive battery cable and starter cable, all one assembly joined at the positive battery terminal as in the original Ex. The short Explorer battery cable is the one that goes to the single lug bolted to the distribution box. I don't remember if the terminal was originally double bolt or single bolt but it has been trimmed somewhat and is a single bolt now. The 5.0 Ex starter harness assembly also contains the negative battery cable that grounds at the front of the engine and at the radiator core support. The negative part appears to be unmodified.
The double Ranger lug at the distribution block ORIGINALLY had two red cables attached, one that went to the battery positive post (and then to the starter) and one that went to the alternator by way of the fusible links. The Ranger cable from the double lug to the battery positive has been cut off and the short stub is heavily insulated with multiple layers of shrink tubing and then convolute and tape. That part is no longer needed because I'm using the Explorer positive battery cable instead.
As far as I can tell, the rest of the Ranger alternator branch with the cable, 2 wires and fusible links is unmodified (except for cutting off the white/black as discussed earlier).
So, the remaining Ranger positive red alternator cable and the Explorer positive red battery cable are joined by bolting down their terminals at the distribution box lugs because it was a convenient place to do so.