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


Project Logs For detailed builds specific to the Ford Ranger, one thread per vehicle please.

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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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Old 07-23-2018
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Nice work!
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Old 07-23-2018
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Quote:
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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Old 07-23-2018
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Quote:
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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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.
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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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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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Old 4 Weeks Ago
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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 2 Weeks Ago
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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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Old 4 Days 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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