So, when I first got this Ute, my step-dad was on to me about doing the cab extension. It took a couple of years to get organized and to find the time to do it. The only pics I have are of the completed job, but if you know what the inside of an X-series Ute looks like, you will see the huge increase in room. Next time we do one, I will take a s**t load of pics, and basically do a tech doco for everyone to enjoy.
The rear panel was removed just below the window, and right down to the level of the rear floor. The front Ute floor section is then cut at the point where the panel will now sit, as part of it is now inside the cabin. The front piece is fitted back into place, and sealed up with something smelly (I can’t remember it’s name, panel beaters use it, and it stinks for about a week). The rest of the floor will go back into it’s original position. We use a piece of angle, welded in place, as a support for the rear floor piece and the rear panel. The rear panel is then trimmed to the right size and fitted back into the Ute using the same stuff they use to fit firewalls, etc, into new cars. No welding at all. Seems strange, but it is extremely strong, and hasn’t moved or cracked at all in over 4 years.
The original rear carpet is trimmed to fit, so it no covers from the cabin floor to the rear panel. The off cuts, and an old EL boot carpet, provided enough carpet to cover the side panels, and I fitted a 6” Sony Xplod speaker on each side. I just need to get a bit of carpet for the rest of the rear panel, and the interior will be complete. I will get to it, I will. It’s only been 4 years or so, no rush.
This would have to be the best thing anyone could do for an X-series ute. It makes SOOO much more room, you can actually recline the seats, you can fit a fair amount of luggage behind there if you need, you can get the seat back far enough to get your big fat gut away from the steering wheel, and anyone more than 6' tall will be able to drive the car without hitting the roof. And, best of all, your woman can put her hand bag/shoes/hat/purse/miata/associated crap behind the seat, NOT ON THE FLOOR!

Pics soon.

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Last edited by sooty72 on Thu Jan 20, 2011 11:32 am, edited 1 time in total.

hey mate good to see the write up is going well. did u notice any change in cabin noise after that extension mod??

It's a bit louder in there now, mainly thru the rear panel. Must get some carpet for that.....
If noise is a big issue, some underfelt or dynamat-type stuff would sort it out. I'm not that fussy though......

yes you would soon fix the roadnoise issue no doubt.. definately a worthwile mod for the taller creature

Ok, a quick update.
We have scored another XH ute very cheap, (It is a '96 XH, not sure about the rest yet, will know more saturday), 4.0, 5 speed on gas, etc. It has a tray liner, and looks like tickford gas. Is this the factory stuff, or just a wanky aftermarket setup? It's very dirty, and hasn't been started for 4 years! It has no radiator (no probs, got a spare) and has a bit of damage to the front of the bonnet, but looks repairable. It has a broken door handle, (standard equipment, isnt it) and a few big scratches, but all seems repairable. I will get it cleaned up and try and get it running this weekend. This gives me all the bits and bobs I need to fit the T5 to my ute. Yay! We will stick an auto back in and will most likely tidy it up and sell it on, maybe even make a couple of grand on the deal.
The only big hassle I can see is that it does not have any keys. Obviously, the door locks wont be a big issue, but I'm not to sure what to do about the ignition. I have a full set of door locks and ignition switch out of an ED (?), but I'm not sure if they will fit. I may have an EL barrel and key, will that fit? Can I fit the entire EL column, if needed?
Pics coming, I'll get some this weekend.

OK, a quick update.
I fitted the ED ignition switch into the XH, had to do the smartlock learning thing, but once that was done it cranked over fine. No fire, but at least it was cranking over.
After a few tries, I figured we weren't getting any fuel, so I took the lid off the airbox, chucked away the air filter, and sprayed some start ya barstard down the inlet pipe. A few cranks and BOOM! She blew a 1/2 tonne of dirt and crap out of the exhaust, and backfired out of the throttle body, and lit up the spray residue in the inlet pipe. A nice little fire for a few seconds, but i smothered it and no damage done. Except to my undies!
I then removed the entire inlet pipe, and disconnected the wires from the lp gas convertor.
Sprayed more start up the throttle body. It started, but only ran for a second or two. No fuel being supplied.
Now, the LPG system is a Tickford system, maybe dealer fitted, as it is tagged 1996, same as the vin tag. It has no lpg guage, it seems to share the same fuel guage between both tanks. I found a broken switch under the RHS of the dash, near the diagnostic plug. If you pull it out, it clicks. With the ign on, you can hear a click under the drivers seat, and the fuel guage jumps from almost empty, to almost full. There is also a large module of some sort under the drivers seat. LPG computer?
I then removed the rear floor and used a multimeter to find 12v power at the pump. With the lpg switch in the guage-empty position, there is power at the pump. Click the switch, guage goes to full, no power to the fuel pump.
OK, so now I have the car set to fuel, power to the pump, but no pump. I located another ute pump, switched it over, but no joy. Then I gave up and went home.
I have since been told that the pump I used was a dud and doesnt work.
I will (hopefully) get back to it tomorow, and we will try another pump and see if it will start.
I want to get it running, and driving, so I can see if the T5 and the engine are any good before pulling it apart.
Pics soon, I promise.

Update:- yesterday was very productive - got it started and driveable!
We removed the fuel pump from the ute, and pirated the pump from an NA lane in the back yard. The mounts ,hoses and wiring were different, but the pump itself was the same. A bit of fernageling and it all worked well. Refitted the pump to the ute, turned the key and i could hear the pump start up. Yay!
After a few cranks it fired up. It runs OK, idles, etc. Needs a tune up BADLY. Should clean up OK though. We fitted the radiator, thermos and thermostat housing from my EF wagon, filled it up with water, topped up the power steer reservoir, removed the broken front bar, and drove it over to the shed. The clutch was a bit draggy, with the pedal very heavy and almost on the floor. We replaced a flat tyre on the back, and I adjusted the clutch cable to get the pedal the same height as the brake pedal. Took it for a drive out on the road, all gears feel and sound good, engine rough but getting better. The fuel smells very musty, probably very stale.
All in all, a good result. The T5 seems good, doesnt jump out of gears, easy to shift, not noisy.
As promised, here are some pics of the thing.






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I got a few pics of the lpg set up. Can anyone tell me if this is a factory fitted system? Maybe dealer fitted? Are they any good?





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It was done by Tickford, at their factory I presume. Fitted before delivery. You ordered it when you ordered the car.

Cool! Thanks guys. I thought it must of been a factory fitted jobbie, as it is really neatly done, and it uses the same fuel guage for both tanks. Neat idea, IMHO.
Not sure yet if we will leave it in there, or if I will pirate it for my ute. Decisions, decisions...

You'll find the ECU will be dual fuel.
Probably got a 95DT-xxxxx number or similar.

Thanks mate, I will have a look at the ECU on Sunday, and get the numbers off it for future info.
As I am raping this ute for all of the 5 speed goodies for my ute, and replacing it with an auto, what should I do re the ECU's? If it is a dedicated dual fuel ECU, will it still work with an auto? Is there a cheap "trick" to make it work? I could then do the resistor bit to my auto ECU, when I fit the T5....
Or do I need to find an auto / dual fuel ECU?


help........

hmm, I suspect you'll be able to use the duel fuel manuel ecu in yours without the gas system, but you will need an auto duel fuel ecu for the auto, Although there maybe a possibility of getting a piggy back setup for the gas system.
got to admit I don't envy you getting parts for that is not an easy task, spewin that I didn't get the bonnet the other day, something in my head can't help but wond how a fairmont front would look on it, hmm, anyone one say grinder.
If you need any help with the conversion just let me know.

Bugger! Oh well, may have to fit the gas to my ute.



The grinder is the easy part, it's the gluing it all back together bit I don't think will be fun or easy. I'm not a fan of the Fairmont / Fairlane front on a ute, but I can see the benefits. I think a standard EL front on an XH would be cool, as a lot of people wouldnt notice it's not stock, and those who do would appreciate the effort that has gone into it. It would mess with the mind a bit, that's for sure.

This may help, I posted it up years ago but no one made it a sticky so it hides deep down in the LPG forum.

Thats the factory Tickford fitted unit fitted to the ute. The module that alters the ignition timing for LPG is built into the ECU. It will still have an AMS module bolted to the steering column.

http://www.fordmods.com/post720327.html?hilit=vialle%20lpg%20ef#p720327

I wouldn't consider putting the LPG into your ute unless the donor ute runs well on both petrol and LPG. No missing at idle, no stalling on deceleration and backfiring.

If you want to see how much performance you will lose from the ute once LPG is fitted; simply fit the intake with the gas mixer ring on to you ute. Block off the gas mixer and take it for a drive around the block. Prepare to be disappointed cos it will have the performance equal to an XF falcon.