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Build for Off Road (2024) Season 2 Episode 6
#Build forOffRoad
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#Build forOffRoad
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FunTranscript
00:00Today in the build for off-road shop I've got this factory 5 XTF truck in here and I've got a pile of work to do to it and I'm doing it all by myself. I have to lift the cab off and replace the engine. I'm going to have to re-gear the truck front and rear as well as go ahead and build a full custom roll cage with some cool seats and I'm going to do it all by myself with no help from anybody else.
00:27Just ignore those people back there.
00:32Today in the shop we have this truck right here. Now if you recognize this truck you're a huge fan thank you very much. This is the factory 5 XTF truck. Now not too long ago me and all the crew from factory 5 well mostly them I just watched built one of these trucks here in the shop. It's absolutely amazing. Gave it to Joey Logano. He's using it to raise money for his foundation.
00:54Now the truck impressed me so much that this year we plan to go on a really cool trip and the crew deserves a cool vehicle to ride around in so we reached back out to factory 5 and said hey can we borrow one of your super cool XTF trucks?
01:09And they said of course you can. You can borrow this one because it's got a blown motor and it needs a cage and some gears and a locker out back. So as long as we do all that work they're going to let us take this out on our adventure ride.
01:23So I said well okay you can bring it in the shop. You guys come down and help and we're going to fix this truck. So that's what we're doing today.
01:29We're basically going to take this really really well abused and we'll see that when we look at how well this truck has held up for some of the abuse that it's been through.
01:37We're going to go in here. We're going to replace the engine. We're going to mock up some seats. I'm going to start working on a roll cage and we have to get some new gears and this thing needs a locker out back.
01:46Basically making it even more bulletproof than it already is. So step one. Best step. Cab comes off. I'm not doing that. They're doing that.
01:59Wait. Oh what about the shifter cable? Got it. Okay. Hold on. Okay.
02:10So the body is now off and Nate's back again. Nate good to have you back in the shop. Good to be back.
02:16All right. So what happened to the motor in this truck or do we even know?
02:21We have a rough idea what happened. This was the test mule truck that we built way back.
02:26It was actually a pre-production truck. Then we went back after we did all the testing, made the jigs for the chassis, put a real production chassis on.
02:33So this is really number one. Did all the testing out with Fox out in Ocotillo, loaned it to some military guys.
02:41I can't really get into that too much, but they had some interest in it and some of the guys.
02:47And then after I got back, it started acting a little weird. I don't know what it's wrong with.
02:51I think there's something wrong with the cams. I don't know if there's a piston problem. It just runs like crap.
02:56So either way, that's broken. That's gone.
02:58But the most important part of this is the fact that this is the truck that you tested.
03:03And by testing it, you didn't just take it down to Cars and Coffee and say, look at my truck.
03:07We tested this truck.
03:08Tried to break it. Yeah.
03:09My favorite part of my job.
03:11Yeah. And so you beat this out to make sure everything works good.
03:13Yep. Never broke a single thing.
03:15And so now when we're talking, yeah, I'd love to let you guys use it.
03:20And I'm hoping we'll be part of the adventure ride.
03:23All right. So our goal here is motor out.
03:25And then I'm going to tackle that front diff while you guys put a new motor in.
03:35We were able to source a low mileage replacement motor from a local recycling yard.
03:40This has about 40,000 miles on it, so it should be good.
03:43But now what we have to do is take everything.
03:45And when I say we, I mean the royal we, like they're going to do it while I do other stuff.
03:49So they are going to change over the valve covers because they want these nice aluminum covers on here.
03:55Also have to change the spark plugs because this motor was a supercharged engine.
03:58And we want those plugs into the new motor.
04:01And I think that's about it.
04:02Oh, obviously all the harness has to be moved from motor to motor.
04:05So just a few things got to swap side to side.
04:07While they're doing that, I'm going to go over and throw gears in the front axle.
04:11Because it's easier to do that, put the engine out of the way.
04:25Now we pulled the front diff out because we're going to re-gear it.
04:28Now the reason we're re-gearing this is because when Factory 5 originally built this truck,
04:33they just added a supercharger to it to get extra power to augment the extra weight from those 37-inch tall tires.
04:40Now that is one way to deal with the extra weight from those larger tires and wheels.
04:43But a better way is to also re-gear the truck because then you can take advantage of all that power that you've added to the engine.
04:51Now we've done the math on this truck and it has a set of 331s inside it right now.
04:55When you do the actual calculation to the correct gear ratio, it came up with something like a 448, which is just a random number.
05:01And then what I like to do is I go up to the next ratio up, especially on an off-road truck because that's going to take advantage of a little bit extra gear ratio for the extra weight of the truck.
05:11Now for our gears, we've got a set of Revolution Gear and Axle gear set.
05:15Now Revolution Gear and Axle, 41 years making gears.
05:19They are veteran-owned and operated.
05:21They are heat-treated for optimum strength.
05:24They are precision machined and they come lap.
05:26And they also have very, very high-quality gears always inside the box.
05:30So when you pull a set of Revolution Gear and Axle gears out, you know that you're going to get a high-quality precision gear.
05:36Always when you get a set of gears, you want to get a full master install kit.
05:39That's going to come with all the bearings, all the seals, new bolts, a crush sleeve if you need it.
05:44Obviously silicone and some gear marking compound and some thread locker at the same time.
05:49Don't just replace some of these parts if you're going to rebuild the front axle or the rear axle in this case.
05:53Just replace all the bearings, just a good idea since you're in there.
05:57And your Revolution Gear and Axle always uses high-quality Timken or coil bearings.
06:01So you don't have to worry about getting an off-brand bearing.
06:03You always get good quality bearings.
06:04Rebuilding a differential is actually not that difficult.
06:07It's just time-consuming.
06:08You need some special tools.
06:10But if you just take your time and ensure that all your specs are set up to the factory specs that the manual comes with with your gear set,
06:17you'll end up with a high-quality gear set ready to tackle the dirt.
06:23Quick tip for you, save the old ring gear bolts when you disassemble your differential
06:28and use those to pull the ring gear onto the carrier.
06:32That way you're not introducing an excessive amount of stretch into your new bolts.
06:37The more you know.
06:38That's opinion.
06:52It's technically my opinion.
06:53With the differential completely rebuilt with our new Revolution Gear set,
07:15now it's ready to go back into the truck.
07:17If we were building basically a hardcore off-road rig, I'd opt to install this heavy-duty Revolution Gear and Axle Diff Cover.
07:24This is quarter-inch thick steel with a 3-8-inch thick flange.
07:28This would protect the gears when we're off-road.
07:30I don't know if we're going to use it on this particular truck because of clearance issues around all of the engine,
07:36everything that's in there from Factory 5.
07:38But if you were building this for hardcore off-road, you'd obviously want to put these.
07:41We'll get one for the rear when we do the rear a little bit later.
07:44The setup turned up perfect.
07:45We have great pattern and perfect backlash.
07:48One of the reasons for that is because of the actual Revolution Gears.
07:52Revolution Gear and Axle guarantees a no-rebox policy.
07:56That means that they're not taking other people's gears and putting them in their boxes.
07:59Every time you open up a set of Revolution Gear and Axle gears, you're ensured that it's their gear.
08:04So it's going to set up the same every single time.
08:06If you're like me and you rebuild a lot of diffs,
08:09the benefit to that is the gears are the same every single time you pull in the box.
08:13So once you have specs in your head, you've done a bunch of similar axles,
08:17you know what the pinion depth shim is going to be.
08:19You know basically what your side bearing shims need to be to get that proper setup right out of the box
08:24because the gear is the same spec every single time.
08:27So while I've been rebuilding the front axle,
08:32Brendan from Factory 5 has been over here playing motors and you've made a good mess.
08:35Yeah, just a little bit.
08:36Quality mess.
08:36All right, so what are you doing and what have we done?
08:39So right now we got the old engine or the new engine torn down.
08:43So then we had to switch our valve covers because the Factory 5 wanted to shove the valve covers back.
08:47Switching all the supercharger pulleys back over.
08:50And then we also found out the oil adapters are different.
08:53So we had to swap those with one sensor.
08:55Okay.
08:56Then we're going to get everything cleaned up, ready to go.
08:58We're going to get our diff put back in.
09:00So then we can get this slip back in and then our harness all together.
09:02All right, good luck.
09:03Well, yes, Brendan, I'll put a diff in.
09:05You can put this in.
09:05Perfect.
09:06I just finished rebuilding the front axle and installed it into the chassis all by myself with no help from anybody else.
09:14And before I put the engine in, I need to fix this small crack in this basically coolant Y that's part of the cooling system on the engine.
09:23We're going to fix it using the JB Weld high heat syringe.
09:26Now, it's specifically designed for repairs like this.
09:29It can handle temperatures up to 550 degrees.
09:31It will cure within 24 hours, but if you need it to cure faster within one hour, you can apply heat to it.
09:39250 degrees for about one hour, and then it'll be fully cured.
09:43So if you're in a hurry, you could simply do this repair and maybe, I don't know, throw it in the oven, heat it up, and then it will be good as new.
09:50Once I get this fixed, I can then install the engine once again all by myself with no help from anybody else.
09:56I work so hard.
10:01Today in the shop, we're working on the Factory 5 XTF test mule.
10:24The guys are getting everything done underneath the hood.
10:26And Nate and I are going to talk about, because this, we've got some big news with this truck right now.
10:30We've got more models.
10:31We do.
10:32So this truck right now is, the current model is 2015 to 2020, F-150, crew cab, four-wheel drive, any model you want.
10:41So if you want leather interior, you get a Lorette.
10:43So whatever you have, that's up to you.
10:45By the end of this year, we're now going to have, it'll be 2015 all the way up to, we believe, 28 is what Ford said is going to be the same cab design.
10:54So if someone wants to go buy a brand new truck, brand new truck, and make it more awesomer, they can do it.
11:00More awesomer.
11:01And with this kit right now, it comes with the 37s, it's getting all new body panels, and it's actually going to be able to take 40s.
11:06Now we talked about this when we built the truck, original truck, you're basically doing a full chassis replacement.
11:11Full chassis.
11:11And what are our suspension benefit numbers after the upgrades?
11:16So you have 16 inches up front, travel, 20 in the rear.
11:20And it's a full four-linked.
11:22Yeah, it's no longer leaf sprung rear, four-link rear, full chassis replacement.
11:26And when someone buys a kit, it's literally everything they need to build the truck.
11:29Everything you need to build this truck besides the actual truck.
11:32So you come up with the F-150, we give you everything else you need, you pick your tires and wheels, just because that's a personal thing.
11:38Yeah, and you said the new one's going to have 40s.
11:4040s.
11:41Yep.
11:41I like 40s.
11:43All right.
11:43Well, while I finish putting this truck back together, all by myself with no help from anybody else, I'll go work on the rear axle.
11:51For the rear axle in the XTF pickup truck, we're going to re-gear it to match the front, obviously.
11:56You want matching gears front and rear, so it's another set of 456s from Revolution Gear and Axle.
12:01But out back, we're going to be adding a traction device.
12:05Now, whether you want to install a limited slip or a POSI or a selectable locker or a mechanical locker, it all boils down to the application of the vehicle.
12:14If this vehicle was going to spend a lot of time on the street and less time off-road, and I just wanted some additional traction when I'm in the dirt,
12:21well, then maybe I would go ahead and choose the Eaton TrueTrack.
12:25This is a helical-style POSI-type differential that basically senses wheel spin, and then will engage both wheels to give us traction when we're off-road.
12:34But if I want, in my opinion, the best of the best, and we're talking about hardcore off-road, it's going to be the Eaton Detroit Locker.
12:43This bad boy is known for its legendary strength.
12:47It will always be locked until it's required to unlock the differential for, like, a tight turn in a high-traction environment, and then it will unlock.
12:57It is perfect for a truck like the XTF.
12:59When you're in the dirt, when you mash the gas, that supercharger spins up, and you want all the engine's power divided evenly between both rear tires,
13:08that is where the Detroit Locker is going to shine, and then it's perfect for this application.
13:13All of this is for the rear axle in the truck.
13:15It's a 9.75 Ford that's been swapped in here, and installing it, super easy.
13:21Woo!
13:22Woo!
13:22Woo!
13:22Woo!
13:23Woo!
13:23Woo!
13:23Woo!
13:23Woo!
13:24Woo!
13:25Woo!
13:26Woo!
13:27Woo!
13:28Woo!
13:29Woo!
13:30Woo!
13:31Woo!
13:32Woo!
13:33Woo!
13:34Woo!
13:35Woo!
13:36Woo!
13:37Woo!
13:38Woo!
13:38Woo!
13:40Woo!
13:41Woo!
13:42Woo!
13:43Woo!
13:44The new gear ratio that we've installed in this truck will help with acceleration, but whenever
13:48you're dealing with a vehicle that you've added oversized wheels and tires to, you want to deal
13:53with deceleration, and that means upgrading the brakes some way.
13:56Now, one of the easiest ways to do that is with a PowerStop Z36 truck and tow package, because
14:03it's everything you need in a couple of boxes just ordered underneath one partner.
14:08You'll get drilled and slotted rotors, front and rear, or drums if your vehicle is equipped.
14:13All new brake pads with a specific carbon ceramic makeup that will match what you're going to
14:18be doing with the truck.
14:19So this is a truck and tow package, so this is designed for heavy applications like our
14:24truck when we're going to be using it under a lot of weight.
14:27And then everything that you need to properly install the rotors and the brake pads.
14:32So all new stainless hardware, all new stainless clips, lube for the sliders, and new boots
14:37for the sliders.
14:38So essentially, aside from rebuilding the caliper, you will have a completely overhauled brake
14:43system.
14:44If you want all new calipers, PowerStop does have that option for you as well for most popular
14:49vehicles.
14:50Another area that you can upgrade at the same time is your windshield wipers.
14:54This is going to sound silly, but it's probably one thing that is the most annoying thing ever
14:59when you go to the parts store and you go to buy new wiper blades for your vehicle,
15:03you're ending up trying to buy one for the right and one for the left.
15:07Well, the new PowerStop PowerClear wiper blade kit comes with wiper blades, both wiper blades
15:14in one pack for your vehicle.
15:16They're vehicle specific, so the clips will match whatever vehicle you order it for, so
15:20no more adapters to deal with when you're trying to make the wiper blades fit.
15:23It comes with a window cleaning cloth, and it even has a UV indicator built into the blade,
15:28so you know when it's time to replace the blades in the future.
15:37Since we had to open up the hydraulic system for the brakes to get the cab off,
15:45and we're upgrading the actual physical components of our brake system right now,
15:50this is a perfect time to upgrade the flex lines.
15:53Now, at the back and the front, we're going to be installing these crown performance lines.
15:57I had them basically send me a factory replacement line, so it comes with a new banjo fitting
16:02and then a new inverted flare fitting at the back, so we'll just install these.
16:05The nice thing about the crown performance lines is they are incredibly strong because
16:09of their multi-layered construction.
16:11The good thing is you can get them in many different colors, but honestly one of the best
16:15things is the fact that they have many different end options to fit any OE or aftermarket application,
16:22and they are all one-piece ends.
16:25There's a lot of companies out there making brake lines where they will basically, you know,
16:28sell you this little banjo fitting that fits on the caliper,
16:32and then there's a small little AN nut at the end that you'd screw the brake line into.
16:37Well, that's a point where the brake system can leak.
16:40Anytime you can eliminate that type of fitting, it just makes the brake system more secure and safer.
16:45So the crown performance having all these options of one piece ends just makes them one of the best in the business.
16:51.
17:01.
17:06.
17:10.
17:12.
17:14.
17:16.
17:17.
17:22Okay.
17:24I think the oil is everywhere now.
17:25Oh, come on! You were worried!
17:26Is that... Is that a normal Ford thing?
17:28Give it a...
17:30.
17:34Alright.
17:35Step one done.
17:37You're welcome guys!
17:38Thank you for doing this!
17:40I'm happy to do that for you.
17:41Thank you. I really appreciate it.
17:42I'm glad I was able to knock that out for you.
17:43Anytime.
17:44God... Yeah, yeah...
17:45Great job.
17:46that and then you can get out of the shop with the xtf from factory five here in the shop doing all
17:51these upgrades to it there is one thing that i suggested that they do from the very beginning
17:56after seeing this truck in action and that is adding a roll cage there is a real fine line
18:02between driving fast off-road in a vehicle like a factory ford raptor and being able to go as fast
18:08as you can in a truck like this with highly modified suspension and once you cross that line
18:14you really should have a good quality roll cage in the truck and this truck definitely needs it
18:19because it can eat up the whoops like nobody's business so i suggested that while we're in the
18:24shop we're going to go ahead get a good cage inside this thing get four really good suspension seats
18:30with high quality five-point harnesses to keep everybody safe in the truck when you're planning
18:36a cage like this there's a couple things you have to pay attention to you want to look at cage design
18:40which we're going to talk about a little bit later but you want to pay attention to the weight of the
18:43vehicle that will actually determine the size of the tubing that you're going to use and then the
18:48actual seat belt so you're going to just rely on the factory shoulder belts or you're going to go
18:51with five point harnesses which we are here five point harnesses you want to make sure that you
18:56always install this anti-submarine belt or it's often referred to as a crotch strap because that is
19:01what's going to keep you planted in the seat and especially keep you from sliding underneath the
19:06belts or the belts working their way up on you a lot of people skip that crotch strap don't do it you
19:11want to have it in there now at the same time we're going to outfit this truck with a couple
19:15extra items that they're going to take with them and with the crew when they come on our adventure
19:19ride and it's a bunch of stuff from our friends at weathertech one of them being this terry cloth
19:23seat cover this truck these seats look amazing and you know what it's like when you're off road
19:28you're getting out of the dirt you're sometimes covered in mud or maybe you're just down at the
19:32beach and you're covered in sunscreen well you can use this quick terry cloth seat cover to simply
19:37throw over either your aftermarket seat or your factory seat and it'll keep it from getting ruined
19:42and then your seats will always look good so we're going to give them four of these to throw on the
19:45truck when they're out on the ride so soft
19:59the cage i'm going to be building in this truck is often referred to as a luxury pre-runner type cage
20:05now it's a little bit tricky to do because when you're building this type of cage what you want
20:08to do is essentially hide as many of the tubes as possible behind trim panels or get them as close
20:14to them as you can there's no way i'm going to be able to get it underneath the trim panel here up at
20:18the a pillar because it fits so close to the windshield but my plan is to have the windshield
20:23removed and that way i can get it as close to the a pillar as it can and even though it'll be
20:28outside the trim panel then come down through the dash and all the way down inside here and i'm hoping
20:33that they can get it inside this trim panel here that way when you're sitting in the vehicle
20:37you won't even really know there's a cage in there and then also it allows us to still use stuff like
20:41these weathertech hp floor liners because they are laser scanned and designed to fit around all this
20:48stuff like the factory trim panels so if i can get the cage in behind all this stuff it won't interfere
20:53with these and these are great we use them on a lot of our off-road rigs they've really helped us out
20:57in the past keeping mud and dirt and anything else coffee spilled because that happens when you're hitting
21:01the whoops at 80 miles an hour the coffee come out of your hand and the nice thing is it'll land
21:05right here in the floor liner and then you can pour it out when you're done racing keep drinking it
21:10i mean i wouldn't so but anyway it's gonna be a lot of work a lot of cutting a lot of bending a lot of
21:15notching and i have to take a bath show all right
21:21well that was a pile of work to get done today gentlemen thank you so much for getting me tools
21:24while i did all that work yeah no problem yeah all right good stuff and thank you for the cage and the
21:29gears all right nope that's no problem next time we'll see this truck it's going to be kicking
21:33up dirt in big bear california as part of the build for off-road adventure ride gentlemen cheers
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