I'm thinking about picking up an Explorer and I'm trying to narrow down the years, but I want mostly old school stuff on it like:
Manual transmission
Manual hubs
Manual transfer case
Manual windows and door locks
Pushrod motor
Non-EGR motor (my '91 Ranger and '95 Aerostar didn't have EGR)

I would also like the following, though:
R134a A/C system (which means about '95 and later)
Headrests in 4 seats (been rear-ended 6 times)

If I had to give up something on the old school list to get headrests, it would be the windows/locks, hubs and transfer case, in that order. At some point in time, it seems like this power/automatic stuff became standard.

What's the last year for the manual transmission and pushrod motor? Can I get a '95 - '97 with everything on my two lists? I've heard that the ECMs right before OBDII kicked in can be somewhat of a frankenstein and difficult at times, but I'm not sure if this is true for Fords or just the imports. Any concerns with that?

Seems like SUVs have forgotten their roots and gone luxury. What a waste. I don't really care for the new stuff. Simplicity is where it's at.

 

The last year for the 302 was 2001, but I'm pretty sure you won't find one with manual anything. Last year for the OHV 4.0 was 97 I believe, and you are more likely to find manual stuff then, but rare as hen's teeth. These things were marketed as soccer mom cars that dad would be ok to be seen in, so power stuff was the norm.

 

By "manual transfer case" do you mean one with a physical shift lever, or just one where you can select (via push button) whether it's 2WD or 4WD? I'm not sure even the first Explorers had lever-actuated transfer cases.

You won't find factory installed manual hubs in an Explorer 1996 or newer, and I'm not sure if they had them on the 1995 or not.

All vehicles sold in the US starting in 1994 had to use R-134a in the HVAC system. The EGR system is pretty much standard with OBD-II, and all vehicles sold in the US starting in 1996 had to be OBD-II compliant. One of the big pushes in the OBD-II system was emissions monitoring (along with some standardization) and the EGR system is pretty much all about emissions.

-Rod

 

I was referring to a shift lever, and don't want full-time 4WD or AWD.

 

All Explorers at least in your year range had electric transfer case shift. 95 was the start of unit bearing hubs, so no manual hubs from then on. AWD Explorers didn't have anything to disconnect the front end, so that eliminates a potential failure point, but I haven't had any issues with mine so it may just be a non-issue. Anything can fail without maintenance, I'd rather have something complex that's been maintained than something simple that's been ignored.

 

You bring up an interesting point that I hadn't considered. I have a different reason for disconnecting the front end, though. I like to do donuts in the parking lot when it snows and generally get squirrely. It's not nearly as much fun when you have 4WD or AWD. I like the machine to do what I want it to do, not what it thinks I should be doing.

 

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I believe 95 was the last year of a 2wd setting, the rest were either 2wd only or had AWD/Lock/low lock. 95 was also the first year for true independent front suspension, instead of the TTB system.

 

Even in the 1st generation Explorers (91-94) there were some differences. My 94 Ex has an EGR system where my 92 didn't. All of them have the push-button selector for 4WD, but all it does is move the transfer case input shaft just like a manual lever does. You can still disengage the front axle completely to do donuts! The hubs are a crap shoot, since most prior owners have already switched out the problematic automatic hubs to manual hubs, although my 92 auto hubs worked very well until the wreck! All 1st gen explorers were push-rod engines, and both mine were auto transmission, so I can't speak for the manuals. My 92 had RABS (rear antilock brakes) which the solenoid valve froze up so I just bypassed it. It doesn't work very well anyway. The 94 has 4 wheel ABS, and I haven't utilized it much. Both Ex's were XLT models. My Ranger (when I had it) had pretty much an identical drive train as the 92 Explorer.

 

Mikeman from what I've read about what you want I think I would narrow it down to one year for the Explorers. 1994. Here's why:

1 Manual Trans Available

2 Manual Hubs

3 Manual windows and locks

4 Yes you can get a manual transfer case
Borg Warner 13–54 part-time four-wheel drive transfer case. The 13–54 was available with either "Touch Drive" electronic push-button shifting or manual lever-operated shifting. (Wikipedia)

5 Pushrod 4.0 motor

6 R-134 Refrigerant

You may have EGR but it will surely be rudimentary compared to the newer stuff.

 

The first Explorer I ever bought had manual transmission, manual hubs and

A manual transfercase. It was a early 91 model, special order.

 

i've seen many 91-94's with manual t-case lever. even a eddie bauer!


the true fully mechanical AWD t-case found in 96-01 5.0 V8 explorers has TQ split that allows alittle more rear wheel power and they can do a MEAN donut! very easy to get sideways. plus the 5.0's are SO reliable(motor,tranny,t-case) thats my pick for a explorer.

 

Thanks, all. I shall take your inputs under advisement and see if I can find something decent.

 

I stand corrected on the 4wd selector! The electric is all I've seen, but apparently there's options. Good luck in your search

 

my 1st Explorer was a 91' 4.0, Auto, with manual Shift T-case and Manual hubs, was a Nice ride,,Blue and Sliver, traded that in for my 95' F-350 Powerstoke.