Colin's '04 4.0L RWD Edge Build - Ranger-Forums - The Ultimate Ford Ranger Resource

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Colin's '04 4.0L RWD Edge Build

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  #1  
Old 07-03-2018
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Colin's '04 4.0L RWD Edge Build

Finally started the suspension upgrade on my '04 4.0L RWD Edge. Started out simple with some new rear shocks. Tossed on some Rancho RS5000x on the rear to replace what I believe to be original motorcraft shocks. Im sitting at 180K miles, and these things were pretty nasty. When i compressed it by hand, it sounded like a 4 year old blowing bubbles in chocolate milk. Thats pretty bad, in my opinion. With the new Rancho shocks, the rear end doesn't bounce around as much on speed bumps, and I haven't taken the truck out to some pot hole filled streets of San Diego yet to see how the road quality feels.

Overall, took about 15 minutes a side to do the swap, so easy enough to do after work today. This weekend, I'll be heading to the junk yard to find a bronco or ranger rear sway bar to put on. Hopefully, the yards down here have at least one with the rear bar.

I'm currently waiting for my Fox coilovers to come in and get tuned from Down South motorsports, then I'll be doing the coilover conversion from Shawn's hard work. That one is getting a bit flashy, as I'll be powdercoating the brackets to match the eibach springs.

A few pictures from today. More to follow as I make the upgrades!
Original Motorcraft
Motorcraft vs. Rancho
New hotness thrown on
Eibach coil springs. Shawn's brackets will be powdercoated to match.
 

Last edited by HawaiiRanger04; 07-03-2018 at 03:14 PM. Reason: Changing title to project log.
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  #2  
Old 07-22-2018
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So, I'm still waiting for my coil shocks to get here from DSM. They didn't have any in stock, so I'm waiting for Fox to send them out. While I wait, I didn't want to swap my control arms, inner/outer tie rods today, so I decided to build a storage box for the back on the cab. I've got the two door super cab, so it's really easy for stuff to end up piled in back or end up under the seat. Hopefully, this will help me keep organized for the items that live in the truck (straps, fire extinguisher, IFAK, surf wax, blah blah).

I based the box on the design by VH5150 in his How-To post a few years back (the search button does wonders!!!!)

https://www.ranger-forums.com/how-di...ge-box-131508/

So, a YUGE thanks to @VH5150 for having built something that was just what I needed.



Started by removing my seats to have easier access and taped down the physical space the box will take.



I took this picture prior to finishing the taping, so I'm missing some tape markings



Once I had the dimensions, I started the fun part. It's 50" across, 18" deep, and 8" high. The transmission cutout is 2" high, 10" wide.



Finding center line of the cab was... difficult. One moment I've got it, the next I'm 1/2" off.



1/2" dado joints will hold the 1/2 birch plywood floor to the sides and the front.



Getting it square so I can measure and cut for the floor boards.



Not too bad



All four bulkheads are square to the face



Full dry fit. The center shelf will hold a fire extinguisher and my med kit, and will be left open. I haven't built the lids yet, I'll build those once I have the frame completed and all glued up. I'll do the glue up next weekend, as this week is going to be busy at work, and with Comic-Con in town, I dont want to be working on the truck/have the garage open with all the crazy randoms walking by.
 
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  #3  
Old 07-23-2018
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Nice work!
 
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  #4  
Old 07-23-2018
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Originally Posted by HawaiiRanger04 View Post
with Comic-Con in town, I dont want to be working on the truck/have the garage open with all the crazy randoms walking by.
This made me lol...

Hang a sign on your garage that says "Harry Potter Sucks"
 
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  #5  
Old 07-23-2018
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Originally Posted by Apexkeeper View Post
This made me lol...

Hang a sign on your garage that says "Harry Potter Sucks"
nah man, its bad. I live just outside of downtown, so all those people are parking in the neighborhood and walking down to CC. It's awful
 
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  #6  
Old 07-29-2018
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Well, I finished the construction aspect of the box today. This week, I'll sand it down, seal it, and get some carpet to cover it. I'll probably bolt down some climbing tubing to act as a handle, and use fender washers to keep it from fraying apart. I ended up removing the cargo hatches from the sides, and I was able to use the hinges from those on the lids, and even with 3/8" plywood, I'm still able to get about 75% lift on the lid, which is more than plenty to get access to the box.
 
Attached Thumbnails Colin's '04 4.0L RWD Edge Build-20180729_093917.jpg   Colin's '04 4.0L RWD Edge Build-20180729_093939.jpg   Colin's '04 4.0L RWD Edge Build-20180729_105044.jpg   Colin's '04 4.0L RWD Edge Build-20180729_105050.jpg  
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  #7  
Old 08-11-2018
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Alright, this thread is well beyond a suspension upgrade, someone should update the title to Colin got bored one night and read ALL of the project logs since 2007.... DSM called this week and said Fox is making the coil shock and I'll hopefully have it before the weekend. I've got everything to do the coil-over conversion, so looking forward to the tweaking that it going to need. On another note, I ended up installing sound deadening mat today. My goal is to get at least all the rear area done this weekend before I run out of deadening material. I've ordered more and hopefully it gets here tomorrow early enough that I wont have my truck back together. I'm going to install Component speakers in the front and some mid range speakers in the rear once I'm done with the sound deadening.


I sealed the box yesterday and today was the 2nd coat, so hopefully tomorrow I can start with the carpet and get that into the truck when I'm done with the sound deadening. I didn't use a square when I was marking the holes to drill for the fire extinguisher, so its slightly crooked, which irritates the **** out of me. I might move it to the other side and drill those holes once I have the carpet installed on it.


When I pulled the passenger side kick panel, I found this relay unplugged, and there isn't anything that it looks like it plugs into. Is that hole just to mount it to the side? or is that supposed to plug in somewhere? I have no idea.

 

Last edited by HawaiiRanger04; 08-11-2018 at 07:50 PM.
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  #8  
Old 08-19-2018
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Degreased the frame around the arm mounts, cleaned off the old paint
New arm and tie rods. A few coats of chassis paint on the frame and mounts as well
 
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  #9  
Old 09-06-2018
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Picked up my Fox 2.0 Coil-overs from DSMS. They re-valved them for mostly street driving, and I'll be installing them next week.
I noticed that the washer for the upper bracket doesn't fit. It sits on the welds, and it about 1/8" off of the top piece of the bracket. I'll probably just grind off the sides a bit until it sits flush. It is like that for both brackets. I'll be running Eibach 600lbs springs.

I'm looking forward to getting these on, and getting the front end all dialed in!
 
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  #10  
Old 4 Weeks Ago
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So, correction to my previous post, I'm running 650lb springs, not 600lb.

Anyways, got my coilover conversion finished up and I'm back on the road. Holy smokes, talk about an improvement. Road feel is so much smoother, hitting speed bumps no longer jolts the truck up and down and side to side. I'm amazed at how much quieter the ride is, not from road noise, but suspension noise. The old ball joints and tie rods were all shithoused and blown out. When I would hit a speed bump, everything would creak like the whole frame was about to fall apart. I hit some speed bumps today at 25 mph, and while the truck went up and down, it was basically silent and the movement wasn't nearly as bouncy as it used to be.

The only thing I'm worried about right now is the driver side upper bracket's 1/2" bolt and spacer. I have that sucker cranked as tight as I could get it (with a big *** breaker bar) but I think I ran out of threads. I'm completely compressed on the lock washer, but I can still spin the whole bolt relatively easily. I'm going to monitor it over the next couple of days, and if I need to, I'll go get a 1/2" shorter bolt to swap in there. The passenger side didn't have that issue, so I think it has to do with the thickness of the driver side coil bucket being just slightly thinner, allowing the nut to sit lower on the bolt. I'll keep an eye on it, but hopefully that lock washer is engaged enough to keep the nut on...

I'm at work now, but pictures to follow when I get home.
 
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  #11  
Old 3 Weeks Ago
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So, question for anyone who sees this: I found a 2011 Ranger Sport that was in a front end collision, front passenger side got smashed pretty good, and I noticed the rear axle has disc brakes. I'm waiting for a reply on the axle code, but if its an 8.8 with better than 3.73 open gearing, I'm probably going to pick it up and swap it in. So, here is the question, is there a difference in the drive shaft mounting in the 2011 from the 2004 Edge? i.e. longer/shorter shaft, same size mounting, different depth diff housing, or would that be a direct swap? I haven't seen anything that would lead me to believe its a different housing shape, so I'm expecting it to be a direct swap.

I might also pull the rear sliding window and swap my solid window out. Decisions... Decisions.
 
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  #12  
Old 3 Weeks Ago
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Time to update the plans - talked to the yard that has the wrecked ranger, and they want 300 for the axle, $75 for the rear sliding window, $75 for the tow hitch, and I lost interest in their stuff at that point. Guess I'm back to the u-pull yard this weekend in search of a better axle. I'm going to look into the cost of having new bearings, seals, gears and a locker thrown into my current axle first, before I pull that trigger though. I'm installing new Rockford Fosgate speakers this weekend, and I'm on the hunt for an alpine amp as well for the inside. I'm also finally getting around to wrapping the box in carpet finally. Its been a busy few weeks with the suspension and other non-truck related things. I'm going to get some updated pictures this weekend once I finish the speaker install and get the box tucked in.
 
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Old 2 Weeks Ago
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So, I did a thing today.... and bough a single channel amp and a 10" sub. Picked up an RF P3D2 subb, powered by an RF R750D1 amp. I'm going to mod the box to have the passenger side compartment a sealed compartment and I'll mount the sub facing up and the amp next to it. I installed my Rockford Fosgate T16s in the doors and mounted the tweeters in front of the door controls. Going with some 6x8s in the rear soon and I'll amp those as well. My tweeters are mounted on the angled base, so they protrude out a bit. I didn't want to commit to the flush mount just yet.
 
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  #14  
Old 2 Weeks Ago
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Alright, catching up on pictures from the last couple of weeks.

Finished my coilovers, finished the Rockford Fosgate T165s/T-1S install on the front doors.




The finished install of the Coilover. Turned out pretty well, I just need to install limit straps, which will be mounted to the side of the control arm and the frame.
the front side. I'm sitting at full droop on the jack here, and this was taken before I finished setting the height.
As she sits today. I'm pretty happy with the ride on 650# springs. Might bump to 700 or 750, but for now, I'm happy.


Change of plans on: Storage box. Making it a sub enclosure on the passenger side while keeping the driver side storage (vehicle recovery equipment). This is my current project to finish by next week.



Future plans for Nov/Dec: Find a god damn shell at isn't $1000. Seriously, I'll make a road trip anywhere south of Colorado and west of New Mexico at this point. Then do my camper build in the back. I'll probably use three 2x6's for the main frame of it, allowing for half-bed drawers, and then some top entry storage on less frequently needed hardware. I'll also have storage on the front of the wheel wells, the rear will be more of a utility area; electrical panel on the side, wired to a low load inverter and a battery. I'm looking into various ways to charge the batter (dont want to install a small solar panel, but with some removable mounts, that might end up being what I do.



So, disclosure on what led me to start doing these upgrades. I'm in the USMC Reserves, and I'm being mobilized to deploy back to Afghanistan. I've always wanted to build my truck into something sweet (2WD was a bad idea in the long run) but when this came up a few months ago, I decided I wanted to get my truck to what I've wanted for a long time. When I get back, the girlfriend and I are going to take a few months and travel, and we want a pimp *** setup. That led me to come back here this spring and start pulling ideas from all you clever people. I figured I should disclose that so you guys kind of understand where all this is coming from.
 
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Old 1 Week Ago
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Alright, its been about a month or so that I've had the 650# spings on and overall, I haven't had to adjust the springs since I set my ride height when I finished the install. However, I had to put so much preload on the springs, that I'm pretty sure I'm hitting coil bind on speed bumps. Now, these are 10" 650# springs, so I'm wondering if I need to bump up to 700 or 750 since I'll be adding more weight to the rear once I add the shell and platform in the back and I'll probably get a bumper and winch for the front, so there is a bit more weight I'll need to plan for. Normal street driving is smooth as silk (as silky as a ranger can get I guess) right now, but its an empty truck for a few more weeks.
 
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Old 1 Week Ago
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Thank you for your service man.
 
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