Pre-Runner Ranger Part 1

(NARRATOR)>> TODAY WE'RE GETTING OUR LONG TRAVEL SUSPENSION INSTALLED ON OUR PRERUNNER RANGER. THEN WE'RE BUILDING UP OUR NEW REAR AXLE, AND MOCKING IT ALL IN PLACE TO MAKE SURE IT FITS. IT'S ALL RIGHT HERE ON XOR.

(JEREMY)>> HEY GUYS, WELCOME TO XOR. NOW IT'S BEEN A WHILE SINCE WE GOT BACK ON OUR PRERUNNER RANGER, AND WE'VE DONE A COUPLE OF THINGS SINCE YOU SAW LAST. LIKE WE REMOVED ENTIRE FRONT CLIP SO WE CAN PUT THIS MONSTER COYOTE IN BETWEEN THE FRAME RAILS. NOW BEFORE WE GET STARTED WITH TRYING TO PUT THIS IN THERE WE'RE GONNA GO TO THE BACK OF THE TRACK AND HANG THE SPRINGS AND THE AXLE. THAT WAY IT'S ONE STEP CLOSER TO BEING A ROLLING CHASSIS. WAY BACK BEFORE WE EVEN REMOVED THE FRONT CLIP WE NEEDED TO GET RID OF THE ORIGINAL THREE LITER VSIX. NO MORE AIR CONDITIONING!

(ELIZA)>> ALL RIGHT.

(JEREMY)>> GOOD? IT MADE A WHOPPING 155 HORSES WITH AN ANEMIC 180 POUND FEET OF TORQUE.

(ELIZA)>> GOING UP!

(JEREMY)>> WELL IT'S GONNA COME OUT ONE WAY OR THE OTHER.

THAT RIGHT THERE IS A THREE LITER.

(ELIZA)>> AND THAT'S A WHOLE LOT OF ENGINE BAY.

(JEREMY)>> THIS IS THE SUSPENSION THAT'S GOING UNDERNEATH THE REAR OF OUR PRERUNNER, AND THIS IS A 64 INCH CHEVY LEAF SPRING. WELL WE TOOK THIS APART SO WE COULD SHOW YOU GUYS HOW THIS IS ALL GONNA WORK, BUT IN ORDER TO PUT THIS IN OUR PRERUNNER WE'RE GONNA HAVE TO MOVE A COUPLE OF THINGS. AND WHAT WE'RE DOING UP FRONT IS TAKING THE SPRING MOUNT THAT WAS IN THIS LOCATION AND WE'RE JUST GONNA MOVE IT FORWARD ONE BRACKET LENGTH. AND FOR THE REAR WE'RE GONNA TAKE THE STOCK SHACKLE MOUNT, FLIP IT UPSIDE DOWN, AND WE'RE GONNA MOVE IT BACKWARDS TO ACCOMMODATE FOR THE LONGER SHACKLE ITSELF. AND WITH ALL OF THOSE PIECES IN PLACE IT'S GONNA ALLOW OUR REAR SUSPENSION TO FALL AWAY AND HAVE MORE DROOP, AND AT COMPRESSION IT'S GONNA LET THE SHACKLES STAND UP HIGHER, GIVING US MORE TRAVEL.

STEP ONE IS GRINDING AWAY THE REMNANTS OF THE OLD RIVETS, ALL EXCEPT FOR ONE, A VERY IMPORTANT ONE.

THAT'S WHY I DIDN'T GRIND THAT RIVET OFF COMPLETELY. THAT'S ACTUALLY GONNA BE THE ONE RIVET THAT'S GONNA KIND OF LOCATION THIS. NOW I'LL MARK THE HOLES FOR US TO DRILL WHERE WE'RE ACTUALLY BOLT THESE TO THE CHASSIS, AND I'LL PROBABLY WELD THEM ON A LITTLE BIT. NOW YOU KNOW WE HAVE AN APPROACH TO DRILLING THICK METAL. HERE WE NEED TO END UP WITH A HALF INCH HOLE FOR OUR GRADE EIGHT BOLTS. SO I'M STARTING WITH A THREE SIXTEENTHS BIT. THEN MOVING UP TO A THREEEIGHTHS, AND FINALLY TO A HALF INCH. THIS IS NOT ONLY LESS STRESSFUL ON THE DRILL AND DRILL BITS, IT'S LESS STRESSFUL ON YOU. WE'RE JUST GONNA KIND OF BOLT IT ON HERE. WE CAN COME BACK, WELD IT UP LATER. THEN WE'VE GOT TO GO TO THE BACK, AND WE'RE GONNA MAKE A PIECE TO EXTEND THE CHASSIS IN THE REAR. SO I'M USING A THIN CUTOFF WHEEL THAT WILL ALLOW US TO MAKE THE END OF THE CHASSIS SQUARE FOR OUR NEW EXTENSION. TO ADD STRENGTH ON THE INSIDE OF THE CHASSIS I'LL BE ADDING A FISH PLATE, AND THAT'S GONNA TIE OUR STOCK PIECE TO OUR NEW PIECE. AND AGAIN, OUR GRADE EIGHT BOLTS FROM INDUSTRIAL DEPOT HOLD EVERYTHING IN PLACE. NOW WE CAN PUT THE SHACKLE ON.

JUST LIKE THAT FOR MOCK UP, AND NOW WE CAN PUT THE SPRING ON.

COOL! NOW THIS SHOULD ALL FLEX OUT AND FLATTEN OUT ONCE WE GET SOME LOAD ON IT, AND I WILL OVER AND DO THE EXACT SAME THING ON THE OTHER SIDE.

(NARRATOR)>> UP NEXT WE'LL BUILD UP OUR REAR AXLE, AND LATER WE'LL DO A TEST FIT.

(JEREMY)>> HEY GUYS, WELCOME BACK TO XOR. NOW THAT WE'VE GOT THE REAR SUSPENSION DONE IN THE PRERUNNER RANGER WE'RE GONNA GO AHEAD AND START ASSEMBLING THIS FABBED NINE INCH REAR AXLE. BUT BEFORE WE GET TO DO THAT WE'VE GOT TO CLEAN IT UP A LITTLE BIT BECAUSE IT GOT KIND OF DIRTY IN SHIPPING.

MOSSIER SHIPS THEIR AXLE HOUSINGS BARE. SO WE'LL START BY INSTALLING THE INCLUDED STUDS WITH A LITTLE BIT OF PERMATEX THREAT LOCKER, AND HERE'S A LITTLE TIP ON HOW TO TIGHTEN THEM DOWN ALL THE WAY. THE OLD TRICK OF USING THE TWO NUTS, TIGHTENING THEM AGAINST EACH OTHER, AND THEN SPIN THE TOP ONE. THAT WILL DRIVE EVERYBODY DOWN.

IT'S TIGHT. NOW I CAN LOOSEN THEM BACK UP.

AND TO KEEP ALL THAT GEAR OIL INSIDE MOSSIER PROVIDES A PRECUT GASKET.

NOW A LITTLE PERSUASION IS NEEDED SEATING MOSSIER'S PREASSEMBLED CENTER SECTION SPORTING 5.13 GEARS, AND INSTEAD OF A LOCKER WE'RE GOING WITH A GOOD OLE FASHIONED SPOOL.

THIS WHOLE AXLE WILL HAVE TO COME APART LATER. SO WE WON'T TORQUE ANYTHING DOWN FOR NOW.

(ELIZA)>> MOSSIER'S MNINE FAB HOUSING MEASURES 65 INCHES WIDE AND SPORTS 35 SPLINE AXLE SHAFTS THAT END IN HALF INCH STUDS ON A FIVE AND FIVE AND A HALF BOLT PATTERN. NOW WE'RE USING A BIT OF ASSEMBLY OIL JUST TO MAKE SURE THAT NONE OF OUR GEARS AND SPLINES ARE ANY OTHER CONNECTION HAVE A DRY START. MAKING FOR EASY ASSEMBLY, THESE AXLE SHAFTS ALREADY COME WITH THEIR BEARINGS AND SEALS PRESSED IN PLACE.

WHEN SEATING AXLE SHAFTS YOU'RE DOING IT BLINDLY, BUT YOU CAN FEEL WHEN THE SPLINES ALIGN AND ARE FULLY ENGAGED.

IT'S IMPORTANT THAT THE SEAL ITSELF GETS A SHOT OF LUBE SO THAT IT SEATS WELL AND DOESN'T TEAR. INSTALLING THE REAR DISC BRAKE CONVERSION KIT THAT COMES WITH OUR AXLE STARTS WITH PUTTING THE AXLE FLANGE BRACKET AND SPACER OVER THE AXLE SHAFT...

...AND CONFIGURING THEM TO BE BOLTED TO THE END OF THE HOUSING SO THEY WILL ACCEPT A CALIPER BRACKET. THEY ARE HELD IN PLACE WITH TBOLTS.

UP NEXT ARE FOUR HEAVY DUTY BOLTS THAT THE CALIPER BRACKET WILL MOUNT TO.

ONCE THIS ASSEMBLY IS SECURED TO THE HOUSING, EACH BOLT GETS A SPACER AND THE KIT COMES WITH A VARIETY OF SPACERS TO BEST ACCOMMODATE YOUR APPLICATION.

LIKE JEREMY SAID, THE ENTIRE REAR AXLE WILL COME APART PRETTY SOON. SO WE WON'T TORQUE DOWN THE CALIPER BRACKET FOR NOW.

AND TO MAKE THINGS A LITTLE EASIER THE KIT'S ROTORS ARE DRILLED FOR BOTH FORD AND CHEVY BOLT PATTERNS. AND ONE LAST CONVENIENCE, THE CALIPERS COME FULLY LOADED.

OF ALL THE FLUIDS IN YOUR RIDE, WITHOUT A DOUBT ONE OF THE MOST IMPORTANT IS YOUR BRAKE FLUID. NOW WHEN YOU HEAR THE NAME PRESTONE YOU AUTOMATICALLY THINK ANTIFREEZE, BUT THEY ALSO MAKE DOT THREE HIGH TEMPERATURE SYNTHETIC BRAKE FLUID. PRESTONE ENGINEERED THIS HIGH TEMP FLUID WITH A MINIMUM BOILING POINT OF 460 DEGREES, AND ITS SYNTHETIC FORMULA PROVIDES YOU WITH A HIGHER MARGIN OF SAFETY WHENEVER YOU HAVE AN EMERGENCY BRAKING SITUATION. PRESTONE ALSO DESIGNED THEIR DOT THREE HIGH TEMPERATURE SYNTHETIC BRAKE FLUID TO NOT ONLY WORK WITH YOUR DISC, DRUM, AND ABS SYSTEM. IT ALSO PROVIDES CORROSION PROTECTION FOR YOUR ENTIRE BRAKING SYSTEM.

(NARRATOR)>> AFTER THE BREAK WE'LL MAKE SURE IT'S ALL GONNA FIT, STICK AROUND!

(JEREMY)>> HEY GUYS, WELCOME BACK TO XOR AND THE REAR AXLE INSTALL ON OUR 2002 FORD PRERUNNER RANGER. OUR AXLE ASSEMBLY IS A MOSSIER MNINE. LIKE I SAID EARLIER, THIS IS EQUIPPED WITH A SPOOL. NOW UNLIKE A TRADITIONAL LOCKER, A SPOOL DIRECTLY CONNECTIONS BOTH AXLES TO THE RING GEAR, AND IS PERHAPS THE STRONGEST WAY OF LOCKING AN AXLE. ALL RIGHT, YOUR SIDE IN?

(ELIZA)>> I'M GOOD, YEAH.

(JEREMY)>> THERE IT GOES.

(ELIZA)>> OOH, PERFECT.

(JEREMY)>> YOU'RE IN?

(ELIZA)>> UH HUH!

(JEREMY)>> WE'RE JUST TEST FITTING FOR NOW. SO WE WON'T BE WELDING THE SPRING PERCHES ON THE AXLE TUBE UNTIL WE CAN GET OUR PRERUNNER SITTING ON ITS COMPLETE SUSPENSION, BUT THIS WILL GIVE US A GOOD IDEA OF OUR RIDE HEIGHT AS WE START ADDING WEIGHT TO THE TRUCK. THE PERCHES CAME WITH THE MOSSIER KIT, AND WE GOT OUR UBOLTS AND PLATES FROM SUMMIT RACING.

UBOLTS ARE ALWAYS UNDER TENSION, AND THERE'S NO CYCLIC LOADING ON THE FASTENER, WHICH WOULD LEAD TO FAILURE. ALSO, TO HELP THE UBOLTS MAINTAIN THAT TENSION LONGER NUTS, CALLED HIGH NUTS OR DEEP NUT, ARE PRIMARILY USED BECAUSE MORE THREADS IN THE NUT PROVIDE BETTER HOLDING FORCE. THEY ALSO PROVIDE BETTER TORQUE RETENTION.

THE THREADS ON A UBOLT ARE FORMED BY ROLLING THEM INTO THE METAL INSTEAD OF CUTTING THEM. ROLLED THREADS, EXTRUDED BY DYES, ARE STRONGER THAN CUT THREADS MADE ON A LATHE BECAUSE THEY'RE GRAIN FLOWS IN MORE THAN ONE DIRECTION, FOLLOWING THE CONTOUR OF THE FASTENER.

(ELIZA)>> LIKE WE SAID, WE'RE JUST MOCKING OUR AXLE IN PLACE SO WE WON'T BE TORQUEING IT DOWN, BUT THERE'S SOMETHING IMPORTANT ABOUT TORQUEING UBOLTS. AFTER THE AXLE IS FULLY INSTALLED WITH PERCHES WELDED ON AND THE UBOLTS TORQUED TO SPEC, WE'LL WANT TO PUT A FEW MILES OF HARD RUNNING ON OUR PRERUNNER. THEN WE'LL RETORQUE THE UBOLTS BACK TO SPEC. THAT'S BECAUSE AS NEW SPRINGS LIKE OURS WEAR IN SOME SETTLING OF THE SPRING STACK WILL OCCUR, AND EVEN A MINOR AMOUNT OF SETTLING CAN CAUSE A DRAMATIC REDUCTION IN UBOLT CLAMPING FORCE. [ drill spinning ]

(ELIZA)>> ONCE OUR AXLE IS CENTERED AND SITTING AT RIDE HEIGHT WE CAN MOVE ON TO SETTING THE PINION ANGLE AND MEASURING FOR OUR DRIVESHAFT.

[ drill spinning ]

(JEREMY)>> COOL!

DOWN!

THERE YOU GO.

(ELIZA)>> THAT LOOKS GOOD!

(JEREMY)>> HERE IN THE SHOP WE ALWAYS HAVE A NEED TO HOLD ALL DIFFERENT TYPES OF THINGS IN TIGHT PLACES. FROM ROUND AND SQUARE TUBING, TO BOLTS THAT YOU JUST CAN'T GET A GRIP ON, TO HOSES THAT NEED A LITTLE BIT OF HELP BEING SEATED. WELL MATCO TOOLS HAS A SOLUTION TO THOSE PROBLEMS. THIS THREE PIECE QUICK ADJUST PUMP PLIER SET COMES IN THREE DIFFERENT SIZES, SEVEN INCH, 10 INCH, AND 12 INCH LENGTHS. THEY ARE USEFUL FOR GRIPPING AND HOLDING ROUND, SQUARE, HEX, AND FLAT FASTENERS. THEIR SELF GRIPPING HEX SHAPED JAWS WON'T SLIP OFF ANY SHAPED NUT OR BOLT, AND THEIR SLIM HEAD WORKS GREAT FOR ACCESSING CONFINED SPACES. AND WITH THEIR HARDENED TEETH FOR FIRM GRIPPING AND SELF LOCKING, THESE MATCO TOOL'S QUICK ADJUST PUMP PLIERS ARE DESIGNED FOR DURABILITY AND A LONG LIFE.

(NARRATOR)>> WHEN WE COME BACK WE'LL SHOW YOU THE BRAKE UPGRADES WE DID FOR "PROJECT CREEP IT REAL", STAY TUNED.

(ELIZA)>> HEY GUYS, WELCOME BACK TO XOR. ON OUR XOR ADVENTURE "PROJECT CREEP IT REAL" DID EVERYTHING WE EXPECTED OF IT AND MORE. AT WILDCAT ADVENTURES OFF ROAD PARK AT THE CAT'S DEN WE TOOK ON A BIG ROCK PILE THAT WASN'T EVEN A TRAIL, AND AT THIS STEEP ANGLE THE ONLY THING KEEPING ME IN MY SEAT WAS MY FIVE POINT HARNESS, AND THE ONLY THING CONTROLLING THE JEEP'S DECENT WERE OUR EBC BRAKES. SO WE THOUGHT WE'D TAKE A LOOK BACK AT THE EBC COMPONENTS WE INSTALLED IN "PROJECT CREEP IT REAL". NOW WHEN YOU'RE OUT ON THE TRAIL YOU USE YOUR BRAKES A WHOLE LOT MORE THAN YOU'D FIGURE. SO EBC SENT US THEIR EXTRA DUTY SUV AND JEEP BRAKE PADS FOR FRONT AND REAR, AND WE'LL ALSO BE USING THEIR GD SPORT ROTORS ALL THE WAY AROUND. THESE ROTORS ARE DIMPLED AND SLOTTED. THE SLOTS ARE DESIGNED TO DRAW COOL AIR UNDERNEATH OUR EBC PADS FOR COOLING, AND THEIR SWEEP HELPS REMOVE DIRT AND DEBRIS, AND THAT IS GREAT FOR TRAIL RIDING. THEIR EXTRA DUTY JEEP AND SUV PADS INCLUDE CALIPER PISTON INSULATOR SHIMS THAT KEEP BRAKING QUIET.

THE PADS THEMSELVES HAVE TWO HIGH VOLUME "V" GROOVES ACROSS THEIR SURFACES. THAT HELPS THEM VENT HEAT BETTER, AND LIKE THE ROTORS, THESE GROOVES HELP REMOVE DIRT AND DEBRIS.

AND THE BEST PART OF IT ALL, INSTALLATION IS AS EASY AS OEM.

THERE IT IS, READY TO GO!

(JEREMY)>> AND ANOTHER UPGRADE THAT SERVED US WELL ON OUR XOR ADVENTURE RIDE WAS OUR EATON ELOCKERS IN THE FRONT AND IN THE REAR OF OUR DANA 60'S. AT DIRTY TURTLE OFF ROAD PARK, ON THE TRAIL "SUPERFLEX", THESE LOCKING DIFFERENTIALS ALLOWED US TO WALK UP THE EIGHT FOOT VERTICAL LEDGE AT THE END OF THE TRAIL WITH EASE.

WITH AN OPEN DIFFERENTIAL UNDER LIGHT LOADS POWER IS EQUALLY DISTRIBUTED TO BOTH TIRES, BUT WHEN THE LOAD IS UNEQUAL AN OPEN DIFFERENTIAL WILL SEND POWER TO THE TIRE THAT HAS THE LEAST AMOUNT OF LOAD ON IT. SO THE JOB OF THE LOCKING DIFFERENTIAL IS TO DO JUST THAT. LOCK THE DIFFERENTIAL TOGETHER SO THAT 100 PERCENT OF THE POWER GOES TO BOTH TIRES AT THE SAME TIME. EATON'S ELOCKER USES 12 VOLT POWER TO LOCK THE DIFFERENTIAL TOGETHER. THEIR DIFF CONSTRUCTION FEATURES NECK FORGED PLANETARY GEARS FOR ADDED STRENGTH BUT LIKE I SAID, INSTEAD OF LOCKING THEM TOGETHER WITH COMPRESSED AIR OR WITH A MANUAL ENGAGEMENT EATON USES AN ELECTROMAGNETIC MECHANISM. AT THE PUSH OF A BUTTON THE ELECTROMAGNET IS ENERGIZED TO LOCK THE GEARS, CAPTURING 100 PERCENT OF THE AVAILABLE TORQUE, SENDING IT TO BOTH TIRES TO GET YOU ON YOUR WAY.

(ELIZA)>> FOR MORE INFORMATION ABOUT ANYTHING YOU'VE SEEN ON TODAY'S SHOW VISIT POWERNATION TV DOT COM.

(JEREMY)>> HEY GUYS, HERE IN THE SHOP YOU HEAR US TALK ABOUT STEERING QUITE A BIT, AND YOU MAY NOT KNOW WHAT ALL OF THESE COMPONENTS DO OR WHAT THEY'RE CALLED. SO TODAY WE'RE GONNA GO OVER STEERING 101. NOW WE ALL KNOW WHAT YOUR STEERING WHEEL DOES, BUT YOU MAY NOT KNOW HOW THIS GETS CONNECTED ALL THE WAY DOWN TO YOUR TIRES. WELL THAT'S WHERE YOUR STEERING COLUMN COMES INTO PLAY. THIS CONNECTS YOUR WHEEL THROUGH THE FIREWALL INTO THE ENGINE COMPARTMENT. AND ONCE YOU GET INTO THE ENGINE COMPARTMENT THAT'S WHERE THINGS KIND OF STEER YOU THE WRONG WAY CAUSE YOU'VE GOT A LOT OF DIFFERENT COMPONENTS TO GO AROUND TO GET ALL THE WAY DOWN TO THE BOTTOM OF YOUR STEERING. SO THAT'S WHERE STEERING SHAFTS COME IN AND UJOINTS COME IN. NOW YOUR STOCK STEERING SHAFT ACTUALLY HAS A REALLY COOL BUILT IN SAFETY FEATURE. THERE'S ACTUALLY A PART IN HERE THAT WILL COLLAPSE IF YOU GET INTO A COLLISION. THAT ALLOWS YOUR STEERING TO KIND OF FALL AWAY FROM YOU SO IT DOESN'T PIN YOU IN THE CHEST. HERE IN THE SHOP WHEN WE HAVE TO DESIGN OUR OWN CUSTOM STEERING THERE'S A BUNCH OF DIFFERENT AFTERMARKET TYPE SHAFTS THAT WE CAN USE, BUT THE ONE WE LIKE TO USE THE MOST IS CALLED "DOUBLE DEEP". NOW THERE'S TWO DIFFERENT SIZES OF SHAFTS. THERE'S YOUR ONE INCH AND YOUR THREE QUARTER INCH. NOW HERE IN THE SHOP WE LIKE TO USE THE THREE QUARTER INCH SHAFT BECAUSE IT ALLOWS US TO PUT OUR STEERING IN THE TIGHTER AREAS. NOW FOR THOSE GUYS THAT DON'T HAVE A WHOLE LOT OF ROOM IN THEIR ENGINE COMPARTMENT THE SMALLER DIAMETER CAN COME IN QUITE HANDY. NOW WE NEED TO HAVE A WAY TO CONNECT ALL THESE PIECES TOGETHER, AND THAT'S WHERE THESE UJOINTS COME INTO PLAY. THESE UJOINTS ARE JUST LIKE THE SAME UJOINTS YOU FIND IN YOUR DRIVESHAFTS. THEY ALLOW YOU TO DIRECT THAT ROTATIONAL MOVEMENT AROUND ANYTHING THAT MIGHT BE IN THE WAY, LIKE YOUR HEADERS OR YOUR ENGINE MOUNTS. THERE'S A LOT OF DIFFERENT UJOINT TYPES OUT THERE. THEY HAVE UJOINTS THAT FIT STOCK APPLICATIONS, OR THEY UJOINTS THAT FIT AFTERMARKET SPLINED APPLICATIONS. AND NOW THAT WE'VE DRIVEN YOU TO THIS POINT LET'S TALK ABOUT THE MOST IMPORTANT PART OF YOUR STEERING. THAT PIECE THAT TURNS THE WHEELS TO THE LEFT AND THE RIGHT. AND THAT CAN EITHER BE A RACK AND PINION, OR A STEERING GEAR BOX. RACK AND PINION STEERING IS FOUND UNDERNEATH VEHICLES WITH INDEPENDENT FRONT SUSPENSION, AND IT IS A PRETTY UNIQUE FEATURE. AS YOUR SUSPENSION TRAVELS UP AND DOWN FROM SIDE TO SIDE YOUR STEERING FOLLOWS THAT MOVEMENT. FOR THOSE VEHICLES THAT HAVE SOLID FRONT AXLES THERE'S THE GOOD OLE FASHIONED STEERING GEAR BOX. ALL YOU HAVE TO DO IS CONNECT SOME STEERING LINKAGES FROM HERE DOWN TO YOUR WHEELS AND TIRES AND YOU'RE HITTING THE TRAILS. NOW FOR SOME OF YOU GUYS THAT MIGHT HAVE BEEN OLD NEWS, BUT FOR YOU NEWBIES OUT THERE ALL WE'RE TRYING TO DO IS STEER YOU IN THE RIGHT DIRECTION AND GET YOU BACK OUT ON THE TRAILS WHEELING.