I have a 1996 Ranger XLT 4wd 4.0 with M5R1 manual trans and 226K miles. I lost fifth gear recently, so decided to just replace the tranny (since a rebuild is around $700!). I found a nice rebuilt one from a 2002 Ranger (92K miles before rebuild) with the same specs as my truck. Clutch is working fine, but I figure I might as well replace it while I have it all apart. Someone mentioned that the later trucks had a heavy-duty clutch setup. Should I order the clutch kit for the '96, or the heaver duty one for the '02 ?

 

You will need to used the 1996 clutch because the 2001 ranger 4.0l was a different engine, same trans bolt pattern(well one extra hole).
To use the 2001 and up clutch you would need to redrill and tap your 1996 flywheel, which you can do, but probably won't want to do.
You can't used a 1998 and up flywheel on a 1997 and earlier 4.0l, they switch from 6 bolts to 8 in 1998

The 2000 and earlier 4.0l OHV engine used the M5OD-R1
The 2001 and up 4.0l SOHC engine used an M5OD-R1HD the HD was added because of the extra bell housing hole and it has a different shifter arm and top plate.

But internally they are the same.

Measure the distance from slave to end of bell housing, I think they are the same but double check that because you may want to use 2002 slave instead of 1996

 

Makes sense. I will order the clutch kit for the original flywheel. I got the replacement slave cyl with the trans, so should be covered whichever one I need when I get ready to reinstall. The kit comes with a new release bearing, which I assume is compatible regardless of slave unit, correct?

 

Yes, I think throw out bearing was the same