I have had this belief that the 1991-1994 Ford Explorer 4×4’s have the potential to be one of the best overlanding rigs to ever be offered by Ford. The Dana 35 TTB front axle is strong and the TTB (Twin Traction Beam) suspension is capable of impressive amounts of wheel travel. They also come with a beefy 8.8-inch rear axle with 31-spline axles. The Explorer is small enough to get into remote places and long enough that you can climb in the back and sleep without having to exit the vehicle.
I’ve been on a search to find good examples of Ford Explorers to share with you and found BKennedy’s 1994 Ford Explorer Adventure Rig over on the Explorer Forum.
The Explorer has a custom winch bumper on the front with a Warn 8500 winch and LED light bar. Custom rock sliders run the length of the body and protect the rocker panels, and there’s a custom bumper on the rear that includes a swing-out tire carrier and Jerry can holder. The roof rack provides space to carry gear and is home to an awning, Hi-Lift jack and LED light bar.
The interior features a B&M shifter, shifters for the Atlas transfer case, Cobra CB radio, Kenwood HAM radio, and 1,100-watt stereo.
The drivetrain is a Ford 4.0L OHV V6, backed by a 700R4 automatic transmission and Atlas II transfer case.
The front suspension consists of a Dana 44 solid axles with an E-Locker and 5.13 gears and is suspended by a pair of coilovers and James Duff radius arms.
The rear suspension consists of a Ford 8.8-inch axle with 5.13 gears, a Detroit locker, and is suspended by a set of custom leaf springs mounted above the axle.
Tires are General Grabber X3’s 35X12.5X15 on 15X8.5 ION Alloy wheels.
Vehicles built today offer very little suspension travel. If a tire is off the ground, it can’t move the vehicle forward. If you have enough suspension travel to keep the tires on the ground, and lockers to send power to all four tires, you’re far more likely to be about to continue forward movement without getting stuck. In the photo below you can see that this Explorer has a great deal of suspension travel, and all four tires are making contact with the ground. If you look at the relation of the rear axle and front axle it’s almost making an ‘X’.
I hope that you can see the possibilities that the Ford Explorer has to offer for the overlander / adventure enthusiast. If you’ve built you Ford Explorer into an adventure vehicle, I’d love to see it. Use the ‘Contact Us’ button near the bottom of the page and send me some pics and details.
To see more photos and all of the build details for this Explorer, see the links below.
Modifications
Front Suspension / Axle:
- SAS with 76 F-150 HP Dana 44 cut-down to Early Bronco width
- 14″ Radflo remote reservoir coilover shocks with Eibach 250/300 coil springs
- James Duff radius arms
- BC Broncos, tie rod over steering. Tie rod has been rebuilt with newer, stronger tube
- BC Broncos track / panhard bar
- Custom shock mounts and track bar mounts fabricated by me
- Eaton E-Locker
- Solid diff cover
- 5:13 gears
Rear Suspension / Axle:
- Spring Over Axle (SOA)
- Custom leaf springs fabricated by North County Spring, Escondido
- Superlift SOA brackets (modified for strength and welded to tubes because they broke)
- Rancho 9000XL 11″ travel shocks
- Custom shock mounts and cross member
- Yukon C-clip eliminator kit
- Detroit locker (used to have a PowerTrax No-Slip but it went boom)
- 5:13 gears
- Differential guard (forget the brand)
Drivetrain:
- Stock 4.0 with 1999 Explorer air intake for relocation due to SAS
- GM 700R4 transmission
- B&M Mega floor shifter
- Atlas II, 3.8 transfer case
- Advanced Adapters for transmission and transfer case
- Custom drive shafts with double cardigan joints on both
- Custom transmission cross member with torque arm and skid plates
- 1006 Liberty power steering pump swap
Tires / Wheels:
- General Grabber X3’s 35X12.5X15 on 15X8.5 ION Alloy wheels
Interior
- Full internal roll cage (custom bent at first cage building party)
- Custom center console with all the accessory switches in one place
- Extra gauges for transmission (PSI/Temp.)
- 1100-watt stereo
- Cobra CB radio
- Kenwood HAM
- Few extra switches
- Extra lap belt for driver (so I don’t have to deal with stock seat belt locking up all the time)
Other Modifications
- Protofab plate front winch bumper (modified to fit from XJ to Explorer)
- Custom light hangers
- Custom front bumper mounting
- Warn 8500 winch
- Custom rock sliders welded to frame
- Custom rear bumper with swing out tire / gas can rack, CB antenna mount and side protection
- Custom roof rack made from 1/2″ and 3/4″ conduit. Spans most of the roof with 42″ curved LED light bar
- Two LED light bars; 20″ CREE flood, 42″ OSRAM curved combo, both have custom made vinyl covers by Zukman
- LED rock lights
- Second battery in old spare tire area (with custom box)
- Puma 12-volt 1HP air compressor and tank mounted with swing down skid plate in old spare tire well next to aux battery
- Battery relay type isolator mounted behind grille, 2 manual breakers and a 450-watt mega fuse, all in line
- Roadmaster auxiliary braking system for “dingy” towing behind RV
- 18 slot auxiliary fuse panel under hood for all the accessories, including radio, most go to secondary battery
- Aluminum water bottle windshield washer reservoir (had to remove stock unit for SAS)
- RedHead steering box with fluid plate cooler
- Electric cooling pusher fan on trans cooler
Links
Bkennedy’s SAS and Rebuild Thread | Ford Explorer Forums – Serious Explorations
BKennedy’s 1994 Explorer | Ford Explorer Forums – Serious Explorations
Photo Gallery
About The Author
Growing up, my father always believed that every family needed a truck—there’s just something about having a vehicle capable of hauling anything at a moment’s notice. That philosophy stuck with me, and it’s been the foundation of my lifelong passion for Ford trucks.
While I’m best known for my work with Ford Rangers, I’ve owned a wide variety of Ford trucks over the years—including F-150s, F-250s, F-350s, and even larger rigs like the Ford Excursion, Ford Expedition, and a 1982 Ford Econoline Sportsmobile camper van. I’ve used these vehicles for everything from family transportation to towing car trailers and campers, and each one has fueled my love for Ford’s versatility and durability.
I especially enjoy the styling of 1970s and 1980s Ford trucks—the bold designs, rugged presence, and classic charm are timeless. Sharing my passion for Ford trucks, vans, and SUVs with other enthusiasts online brings me a great deal of joy, and it’s why I created Blue Oval Trucks.
This website is dedicated to helping Ford truck enthusiasts explore, learn about, and celebrate these incredible vehicles. While I share my expertise and experiences here, Blue Oval Trucks is an independent enthusiast site and is not affiliated with Ford Motor Company.
