RoofHoles11.jpg
0 hits | 87.1 KB | Posted: 3/12/25
This cheap duct tape has been on here long enough for the backing to separate from the adhesive & fibers more easily than from the paint.
(Posted in: Roof Rack & Holes)

RoofHoles14.jpg
0 hits | 123.68 KB | Posted: 3/12/25
The tape was applied over the remains of a self-adhesive foam gasket.
(Posted in: Roof Rack & Holes)

RoofHoles21.jpg
0 hits | 120.35 KB | Posted: 3/12/25
Some 3M Adhesive Remover and a sharpened SpitzNagel (pointy fingernail) plastic scraping tool eventually removed everything with minimal damage to the paint.
(Posted in: Roof Rack & Holes)

RoofHoles46.jpg
0 hits | 133.22 KB | Posted: 3/12/25
Some 3M Adhesive Remover and a sharpened SpitzNagel (pointy fingernail) plastic scraping tool eventually removed everything with minimal damage to the paint.
(Posted in: Roof Rack & Holes)

RoofHoles24.jpg
0 hits | 126.06 KB | Posted: 3/12/25
All the residue came up with paper towels, soap & water, and a little brake cleaner. But the paint/clearcoat has a permanent fog where the adhesive was.
(Posted in: Roof Rack & Holes)

RoofHoles49.jpg
0 hits | 116.54 KB | Posted: 3/12/25
These caps are sold for Ford Transit Connect van roofs, so I thought they'd be good here. Unfortunately, they're much smaller than I expected. But with a generous bead of UltraBlack, they cover 4 of the 5 holes.
(Posted in: Roof Rack & Holes)

RoofHoles37.jpg
0 hits | 126.05 KB | Posted: 3/12/25
After the sealant cured, the excess comes off fairly easily with the same SpitzNagel.
(Posted in: Roof Rack & Holes)

RoofHoles59.jpg
0 hits | 90.49 KB | Posted: 3/12/25
This rubber plug barely fit into the 1 larger hole, but it still got sealed down.
(Posted in: Roof Rack & Holes)

RoofHoles75.jpg
0 hits | 128.49 KB | Posted: 3/12/25
After all the sealant was cured, each hole was tested for several minutes.
(Posted in: Roof Rack & Holes)

RoofHoles78.jpg
0 hits | 95.49 KB | Posted: 3/12/25
None of them leaked, so after some wiring mods, the headliner can go back in.
(Posted in: Roof Rack & Holes)

RoofHoles64.jpg
0 hits | 122.83 KB | Posted: 3/12/25
There were a couple more holes than needed, so they were filled with some extra butyl sealant.
(Posted in: Roof Rack & Holes)

Xbars.jpg
0 hits | 89.01 KB | Posted: 3/19/25
This cheap copy set of crossbars is for '11-15 Explorer roof racks. The poor instructions show the steel nuts inserted wrong, so I had to flip them. And the rear bar was too long, so I had to bandsaw it & re-drill a screw hole. But they look OK.
(Posted in: Roof Rack & Holes)

BodyLHR.jpg
0 hits | 128.15 KB | Posted: 3/12/25
Most PIUs don't have hitch receivers, so it will be added. Aftermarket receivers hang low and don't use as many bolts and don't include a PnP harness, so a factory set is preferred.
(Posted in: Hitch Receiver)

BumpR16d.jpg
0 hits | 127.64 KB | Posted: 3/12/25
The rear bumper cover comes off surprisingly quickly & easily, exposing the plain rear bumper bar, which is attached by only 2 nuts & 2 bolts.
(Posted in: Hitch Receiver)

BumpR16f.jpg
0 hits | 123.79 KB | Posted: 3/13/25
Both muffler hangers also come off since the receiver bolts into those holes, too.
(Posted in: Hitch Receiver)

BumpR16p.jpg
0 hits | 81.16 KB | Posted: 3/13/25
While the cover was off, a break in the energy-absorber was hot-stapled.
(Posted in: Hitch Receiver)

Hrns16a.jpg
0 hits | 106.04 KB | Posted: 3/13/25
Though not originally equipped, the harness is ready for the receiver wiring, which plugs in on the right side.
(Posted in: Hitch Receiver)

Recvr15b.jpg
0 hits | 115.61 KB | Posted: 3/13/25
This receiver came from a '15 Explorer Ltd. that was T-boned on the right, so this was undamaged and fit easily.
(Posted in: Hitch Receiver)

Recvr15e.jpg
0 hits | 112.83 KB | Posted: 3/13/25
Some of the body holes didn't have bolts, so oil is needed for threads to be cut during the first installation.
(Posted in: Hitch Receiver)

Recvr15f.jpg
0 hits | 104.22 KB | Posted: 3/13/25
With some effort, the harness can be threaded between the absorber & cover. This one also has parking sensors & a RKE antenna, but not a liftgate sensor.
(Posted in: Hitch Receiver)

Recvr15k.jpg
0 hits | 109.48 KB | Posted: 3/13/25
The 7-pin plug uses the modern standard USCAR connector, which allows easy swapping to other shapes of trailer connector. The 4-pin is a common rubber receptacle that fits a steel slot welded to the receiver.
(Posted in: Hitch Receiver)

Recvr15n.jpg
0 hits | 117.05 KB | Posted: 3/13/25
The original lower valance can't go back - it would be pushed out in the middle by the receiver. But its red reflectors can be transferred to the receiver valance.
(Posted in: Hitch Receiver)

Recvr16Val.jpg
0 hits | 92.81 KB | Posted: 3/13/25
This cheap copy valance was washed with Dawn & PurplePower, rinsed with warm water, sun-dried for a few minutes, then painted with 8oz of DupliColor EBUN01007 Universal Black.
(Posted in: Hitch Receiver)

Recvr16Val12.jpg
0 hits | 68.5 KB | Posted: 3/13/25
The valance simply snaps into place along the top, with about 9 pushpins along the bottom. The reflectors also snap in easily.
(Posted in: Hitch Receiver)

Recvr16Cvr2.jpg
0 hits | 127.96 KB | Posted: 3/16/25
The cover was prepped the same way, but sprayed with satin black Fusion.
(Posted in: Hitch Receiver)

Recvr16Cvr5.jpg
0 hits | 104.05 KB | Posted: 3/16/25
The cover snaps in very easily, so I'm concerned that it may fall out. I'm considering adding magnets to it.
(Posted in: Hitch Receiver)

Drawbar.jpg
0 hits | 120.55 KB | Posted: 6/5/25
The last piece is a locking adjustable Aluminum draw bar with 2 & 2-5/16 balls.
(Posted in: Hitch Receiver)

ChairPUI-RHF6.jpg
0 hits | 131.62 KB | Posted: 3/16/25
After finding a '15 Explorer Limited in a local JY with good-looking cooled memory seats and carpet, the basic chairs & plastic flooring came out.
(Posted in: HVAC Seats)

Seats15a.jpg
0 hits | 132.72 KB | Posted: 3/16/25
To get the JY seats' rear bolts out, it's necessary to drive their horizontal motors fully forward, and their rear height motors up. The quickest way to do that was to unplug the motors' connectors and use a 12V cordless tool battery.
(Posted in: HVAC Seats)

Seats15c.jpg
0 hits | 134.25 KB | Posted: 3/16/25
They hit the limestone gravel in the JY a few times, but those white marks will wash off easily. In addition to the seats, the '15 Ex.Ltd. also surrendered its floor console & shifter, roof rack, carpet, lower B-pillar covers, and hitch receiver with...
(Posted in: HVAC Seats)

Carpet.jpg
0 hits | 52.55 KB | Posted: 3/16/25
The JY carpets were submerged in rain, so after letting them dry a few weeks, they were beaten out, vacuumed, and installed. The rear was butchered by the person who got the back seats, but that just made it easier to fit with the police cargo floor....
(Posted in: HVAC Seats)

Seats15.jpg
0 hits | 30.68 KB | Posted: 3/16/25
The DSM controls memory for itself, the column, the pedals, & the mirrors. So eventually, I might add those and wire it all up. In the meantime, I'll probably just put 3 buttons on the driver's chair for Set, M1, & M2. Getting the heating & cooling t...
(Posted in: HVAC Seats)

Pass05.jpg
0 hits | 116.35 KB | Posted: 3/16/25
To make its assembly easier, the floor console was installed before the chairs. It wiring and the driver's seat position wiring are underway...
(Posted in: HVAC Seats)

C311-300.jpg
0 hits | 56.64 KB | Posted: 3/16/25
Instead of cutting the dozen wires from the '16 driver's floor connector to splice into the '15s, the pins were simply transferred, leaving the '16 wires intact. 2 power & 2 ground wires from the '15 connectors were soldered into the driver wires to ...
(Posted in: HVAC Seats)

Seats15HVAC.jpg
0 hits | 70.16 KB | Posted: 3/16/25
I haven't decided yet how to control the DCSM, but I may look for something that can connect directly to it instead of passing through 2 networks.
(Posted in: HVAC Seats)

Donor.jpg
0 hits | 70.66 KB | Posted: 3/16/25
This '15 Explorer Limited was T-boned in the RHR door, so most of its interior was intact. A previous customer removed the rear seats & butchered that carpet, but the front seats and shifter console were in very good condition.
(Posted in: Floor Console & Shifter)

Donor04.jpg
0 hits | 120.1 KB | Posted: 3/16/25
Other than a traction control knob and a tow/haul/hill descent button, this console was loaded. The rear HVAC control had been taken, but I wouldn't have needed it anyway. I would like the 110VAC outlet, but I forgot to snag the inverter. It has colo...
(Posted in: Floor Console & Shifter)

Console15.jpg
0 hits | 42.92 KB | Posted: 3/16/25
This collects all the circuits in the floor console into 1 diagram.
(Posted in: Floor Console & Shifter)

ShiftCol2.jpg
0 hits | 104.97 KB | Posted: 3/16/25
I hate the way the column shifter moves, so its 3 T30 bolts & 2 connectors came out first. Unfortunately, I couldn't swap to the non-shifter column shroud because it's made for a power-adjust memory column & pedals that this PIU doesn't have. So it w...
(Posted in: Floor Console & Shifter)

ShiftCblsCpr.jpg
0 hits | 98.48 KB | Posted: 3/16/25
Then ends are too different to use the column cable with the console shifter, so it's a good thing I got the cable with the console.
(Posted in: Floor Console & Shifter)

ShiftCblSwap06.jpg
0 hits | 132.04 KB | Posted: 3/16/25
Swapping the cables only required pulling the fresh air pipe for access to the firewall and shift lever. The front of the column cable releases with a pocket screwdriver, and its grommet comes out of the firewall easily. The console cable has a steel...
(Posted in: Floor Console & Shifter)

TestFit5.jpg
0 hits | 124.59 KB | Posted: 3/16/25
The console won't fit until the upper bracket for the PIU aux. panel is removed, but it's only held in the dash by 2 7mm screws.
(Posted in: Floor Console & Shifter)

Mounts2.jpg
0 hits | 123.21 KB | Posted: 3/16/25
The console takes 2 tunnel brackets not used with the police plate. Some of the police wiring can be used to power the console, but several wires will need to be added or rearranged.
(Posted in: Floor Console & Shifter)

20250304_214008.jpg
0 hits | 87.44 KB | Posted: 3/16/25
The sheer quantity of wires in the console's main connector looks overwhelming. But once organized by function, it becomes very manageable. Top priority goes to the park detect switch because (as I learned the hard way) the BCM will stay awake until ...
(Posted in: Floor Console & Shifter)

20250311_155943.jpg
0 hits | 113.66 KB | Posted: 3/16/25
The column-shift wires were cut in the dash harness and extended through to the right side of the console where its connector is.
(Posted in: Floor Console & Shifter)