Re-posting this since the interior section likes to delete threads..
So here's a write-up for something most people would never even think of attempting. I'm sure some may think "Is that even necessary??". And escpecially for all the modification that went into them. But to me, adding power seats was 100% worth it. You don't realize how much more comfortable the seat is with a few extra adjustments. Really this mod has become one of my favorite things I've done to the truck.
Garrett (weareweird69) presented the theory of this mod to me, and I was the one to put it into practice. 91-94 Ford Explorer seats are basically the same as 93-95 Ford Lightning seats with the exception of the fabric and the tracks mounted underneath them. The power seat tracks from the 91-94 Explorer seats are also fairly similar to the tracks used on supercab OBSs with the power seat option. I also found alot of interchangeability between parts of my stock f-series seats and the 91-94 seats.
I picked up a set of 8 way power seats from a 94 Explorer for $40. These seats were kind of a lucky find since the passenger was full power as well and they were opal gray in color, so the plastic trim from explorer seats matches perfectly.
The day after I picked them up I put a little work into the seats. I checked to see if they were working as they should. I got the drivers side seat completely pulled apart
After that I had a better idea of what I wanted to do. Mounting them in their existing form wouldnt be hard but I couldn't go that route. I plan on cutting down on height in a couple of ways so I can make my goal of adding no less than an inch to the height of the seat
I stripped the seats down to the bone taking everything i thought I could use including the lumbar bags which i now have installed in my rear bench seat.
This is the seat slider nearly at the bottom of its adjustment.
I planned on cutting height by making the seat tracks sit closer to the mounting plate for the seat cushion.
Also here's a comparison of the two plastic pieces the stock handles wont work, so the explorer handle/hinge/spring assembly will go on as well since they are completely interchangeable.
I will be loosing a 1/2" in height and the unnecessary tilt on the sliders. The sliders will now be flat on top like the manual ones. Since the tilt is built into the seat, seat tray, and the power sliders have a tilt control function, so it only made since to try to get the seat lower and resting at a good angle.
I cut off the heads of the rivets and punched them out allowing me to get rid of the middle piece and bolt the top rail of the tracks directly to rail that controls the front tilt.
Heres what the modified drivers tracks looks like next to the unmodified passenger tracks. I enlarged the hole on top rail of the track and used a bolt with some large washers and locknuts in place of the old hinge. I only have on bolt on each side but it has proven to be plent strong. I would have used two bolts but the other side doesnt line up quite that well.
After analyzing them closely I realized that the front tilt is not double hinging. Only the top rivets hinged, explaining the washers and grease between them, and no washers or grease on the bottom. So I saved alot of height by cutting out the middle piece.
The seats still raise and tilt just as they did before. Except the seat tracks sit level fully compressed instead of tilted. Which that is what I want since the manual tracks sit flat.
Another thing that I removed were two tabs that held on the seat belt receiver.
After cutting down the front of the tracks I worked on getting the tracks ready to be mounted to the seat pan.
I measured the holes in the seat pan and the are spaced perfectly with the holes of the front and rear most rivets on the tracks. The tracks are little narrower, but a file will make up the difference in width.
I drilled out the rivets for the legs. And the holes that the rivets used to go through will be the holes that bolt the seat tracks to the seat pan.
With the front legs removed.
Next is to finish up modifying the passenger tracks and then take a little height off the cushion frame.
The factory manual slider is only 1" tall. So far I stand to gain 1.5" of height.
1.5" is still too much for me. While I had the passenger seat out of the truck I was able to conclude that the cushion frames from my stock seats and the explorer seats are identical. Even the slide out leg rest and bolsters on the explorer seats did not differ the design of the cushion frame.
Now with this I now have an extra set of cushion frames to modify to further help my height-reduction.
While I had the seat out I also bolted up the power sliders to my seat just to make sure they bolt up. I only hand threaded 2 of the bolts so dont let the crookedness and misalignment fool you. They bolt up perfectly.
Here's a random shot of the explorer seat next to my stock seat, just for a comparison.
The next phase now is to modify the cushion frames to sit lower on the tracks. I already started modifying one of them and so far I have it sitting about half an inch lower, so I should be able to make my 1" or less goal.
Here they are before modification
The drivers seat came with bolster but since my factory cushions have no means to have side bolsters. And they were in the way of modifying the frame, so i cut off the rivets and punched the mechanism out.
After a couple incisions in the front.
The top of the seat tracks will be recessed into the cushion frame. I slowly bent and used a few hammers to reshape the frame. This allowed me to lose up to 3/4" of height.
This picture above was after a rough cut and only a little bending. I ended making the cut longer so the metal sits flat. You can also see the center strip was flattened out to accomodate a little extra space for the seat motor, since the tracks will be sitting up closer to the frame of the seat.
This picture isnt the best, but this is after the frame has been completely modified. The top of the tracks are now recessed into the frame, allowing me to loose some height.
After that I cleaned everything up and gave it some fresh paint.