I figured it was about time to start this thread. First off, my name is Pete, and I've got a 91 4x4 sport. I started tossing this idea around after seeing too many people go through their trannies, and I wanted to never be stuck w/ a broken tranny.....All is fine right now, but I'm not gonna take a chance. I also am addicted to the sound of a sweet 5.0 and I also wanna have fun w/ a really custom truck.

I searched www.corral.net and came up with a 90 302 HO stang motor. For 800 bucks, I got nearly everything under the hood, back to the tranny. See the pick up of the motor in this thread: http://www.explorerforum.com/forums/showthread.php?threadid=26357

I immediately started disassembling the whole motor, and it is now all in pieces in the garage. Some parts labeled, some lying around, screaming to get lost. After the disassembly, I contacted www.dssracing.com about rebuilding my current motor. I will be turning my block in for a core charge, and they will provide me with a 331 stroked block and running/spinning gear. This is going to cost me approximatly $1200 for this work. I plan on having my stock heads ported and polished and the valves reseated, etc.

My plans are to rebuild a tough motor, with lots of options for future additions. This is just the beginning of a LONG process. I am also planning on mating all of this through a C-4 tranny and a twin stick dana 20. I will most likely use the James Duff swap parts. I've heard nothing but good news about them. This my not look overly fancy, or jaw dropping, but I want a quality install that will be able to withstand anything.

*stepping off soap box*

Thanks,
Pete

Cool you are going with the D20 twin stick! Remember to take lots of pictures and keep us posted.

Lol...yeah, pictures....I do need to take lots of them...I do have some photos But they haven't been devloped yet. Also, the expected time to do this whole deal is the end of July, beginnin of August....but of course...the sooner the better!
:D
Pete

Pete, Sounds like an awesome build! Hopefully mine will be done by then. The only advice I can give is to be patient. There are many things I could have and would do different next time. I hurried in a few places and it actually slowed me down. Now I step back and set small goals on a weekly basis. This week I'm focused on mounting the radiator.

Have fun, and can't wait to hear it.

Well, i've encountered problems, and I havent even started! SCHWEET! Well, when I called about the 331 stroker, I was quoted the price for the kit, and not the built block. The built block is 1800, which is out of my alotted funds. This would use no parts from my stock block in my garage, rendering it useless. As it turns out, a diving buddy of my dads was over and was a porsche mechanic. He took a peek at the the cylinders and says they look perfect. There is no visible wear, and can tell the guy that i got it from didnt beat the motor. In his opinion, there would be no need to be any machining. As I plan now, I will get a 2nd opinion on this, just to be on the safe side, and get a guy I know to build it for me. He's well exprienced in mustangs, and knows what to do with them. (It would also be less expensive this rout, and would still end up w/ stock mustang power, which is still a kick in the ass compared to the 4.0 in there now)

Problem/statement 2: I've been tossing the idea around to keep my T-5 manual. This would save me tons of time and money in getting manual to auto swap parts. Also, the guy who I was going to get my C-4 and Dana 20 t-case hasnt responed to emails. Although he's always been slow, this is nearly 3 weeks slow.(works alot) I'm thinking now, that I can get a fully rebuilt Dana 20 t-case for 400, and get the adapter to my T-5. I think this will come out a lil less expensive(overall), but i will get lower gearing, and it would take me alot less work to hunt down all the tranny parts. I know people will harp b/c im wheelin in the midwest mud...and that manuals can be harder to drive in the mud, but with better gearing, I believe I will do just fine. Thank god I haven't started this project just yet, and am still in the planning stages..... Any thoughts?
(now suffering from carpal tunnel syndrome)
Thanks
Pete

Pete -

One simple word of advice, or actually a revelation: Be prepared for this project to cost you more than you think it will now. Many little things that add up; Gofast can back me up on this, I'm sure.

About DSS: heard quite a few non-favorable things about them from numerous people on the corral. Sounds like you had your own non-favorable encounter.

With your budget, I'd stay away from the stroker. You'll be spending A LOT more money with a stroker, and your durability will suffer. The 331 will have more longevity than a 347, but it still won't last as long as a stock 302, or 0.030" bored over 302, which is a 306. The longer rod lengths coupled with the increased circumference of the crank path of the stroker create more lateral force on the piston, which in turn makes it harder for the rings to make a good seal on the cylinder wall, and also wears the rings faster. Sure, you can make some impressive power with the stroker, but it will cost you down the road with decreased longevity. There are many ways to pull quite a bit more HP and torque out of a normally aspirated 302 or 306. But then again, anytime you increase HP, whatever the method, it's going to cost you money. Something to think about.

Transmissions: Since you already have a T-5, that's the least expensive route. But a built C-4 will be MUCH stronger. Of course the T-5 has an overdrive, which will give you better mileage on the street and highway; the C-4 doesn't. I'm using a built AOD, which solves the overdrive problem, and gives me the auto that I desire. But a built AOD isn't cheap, and it sounds like you're on a pretty tight budget.

Many things to consider, many paths that can be taken, all leading to a badass, custom V-8 Explorer. For most of us, it's a major project that requires quite a bit of knowledge, as well as parts, to be gathered. So take your time and keep learning, the knowledge is out there. The finished product will be something to be proud of.

Well, luckly I've still got a bit of time on my hands....I'm outta school and back to my normal job in less than a month, and then I plan on late July to do the swap. Of course, I'm researching all the time, and right now...My main goal has sorta shifted from somewhat kick ass from the beginning, to reliable, easiest install(if you can even say that) and of course, not digging a grave by over spending money. Now I just want a motor that will last me and what happens in the future from there, is stuff im not worrying about now. Right now, I want to get a 302, under the hood, working properly with out killing myself. I believe the T-5 will do me well while behind the stock 302, and it'll save me alot of cash in adapters, etc. So, the research, and growing of the patience virtue continues.
Pete

I, too, am a poor college student who wants "mo' powa" in his pre-95 explorer. Let me know how all this turns out. I've already decided on most of the stuff for my swap. '93-'96 Mustang 5.0L, AOD, Dana 20 - I've also decided that there will be no professionals involved ;) If i'm going to have a trick truck, escpecially if it's going to be a big modification, I need to know the in's and out's myself. So do you think 5 rednecks, a tree, a chain, and an engine stand could do it? lol.

May the Schwartz be with you.

Ya - Do not forget the redneck girl... (or the be4er!)

Bislam - where are you from? The thought sounds great - would like to see the results...

Jon

I forgot about the chick with beer. There's 5 of us though... we'll need 2 chicks with beer.

Just a thought, what about an OD trans and it's mating TC from a later model F150.
It will bolt up to the 5.0L and should be able to handle the power of a rebuilt engine, even with a small cam.

The adapter from an AOD to a Dana 20 TC is not cheap. The one for a C-4 to D20 is about $600.00. The adapter for the T-5 is proably in that area too.

My '88 Ranger 5.0 swap is using a C-4 to stock ranger TC, knock on wood, but it is still holding together (going on six years now). I would not go C-4 again only because of no OD. Hy-way speed has the engine at approx. 3000 rpm, a little too much for a long run.

If I were to try agin and wanted a good stock, dependable package I would look for low mileage F150 parts, i.e. 5.0L, OD trans, F150 TC, all matched together.

One more thing, although I do not have the number with me at the moment, Ford puts out a small manual to assist the wiring when installing an EFI engine into one that did not have one. This manual show the harnesses laid out and defines all the components and where they go. Also it states what to hook up for power to the main harness.

One more thing, look into part to put the engine in from a Mountaineer or from Ford for a Mountaineer, they have V-8s. The Mountaineer also has a special pulley/brkt arrangement to allow for more room up front.
Using the stock Mustang pulleys and brkts will not allow a mechanical fan and the electric fan S___ !!!

Good Luck on the swap!

Keep it on all Four.

This particular "Bislam" chap hails from the nasty end of God's Country. Texarkana Texas. Over right next to Arkansas

I can agree with that sandy. I started out with a 75 bronc C4 and d-20. As sandy said it SUCKED on the highway, to the point i hated that trans!

Now i'm running a www.gerperformance.com AOD that's coupled to the d-20 by way of advance adapters.

Trans and 11" 2400 converter cost me $1295. I love it, kicks ass!! Shifts with authority! Cost me $70 to ship from Pa. to northern Mi on a semi.

The d-20 yolk took the same u-joint from my stock 1354 and 8.8

http://projectranger.homestead.com/files/aod.jpg

Once i figure out how to properly scan pics that don't take a hour to load i'll have some more up.

I enjoy every minute behind the wheel of my 5.0 ranger!!

NIGHTRANGER5.0,

I think I will look into an GER AOD, I need something more on the Hy-way.

I have had not trouble with the stock transfer case, SO FAR, I think I will keep it.

RFR2212,

Why not stick to a 302, RV cam, etc. 331/347 are designed for racing, reliability is always in question.

I just rebuilt a 5.0L, did a few tricks to it, will let you guys know if it works out. (I am hoping for aobuit 360 ft lbs of torque for a high but I am aiming for about 300+ at 2200-2400 range. We will see!

Let us at the site know what is happening with the engine and what you decide to do.

Tnx,

MY friend has a 331 in his mustang with a NOVI 2000 and Dart Heads. Today he went to the dyno and with 19 psi of boost he made 690 rear wheel HP. I was impressed I hope you guys can make some good power too.
Troll

Nane of the game in the rocks, woods and trailriding is GEARING not horse power.

Where would you use that much power in the woods, well I guess if you want to drag race your truck the HP would come in handy.

I have always subscribed to KISS, "Keep It Simple Stupid" (Stupid is me). I always went for Balls to Wall on everything I built and that is the way I used to drive. Too many broken pieces and I finially realized, what am i doing. Now I build for reliability, reasonable power though.

Good Luck in what ever you decide to do. Build it your way is a good moto, no one to blame it something goes wrong.

Well, there is a small tid bit of info to update here. As all my racing and hot rod buddies told me, I went to the machine shop the told me about. Opal Automotive Engineering located in Streamwood, IL. I went in and a lady took all my info and told me to back up the the garage door to unload. Here I was greeted and helped by one of the employees. After unloading alot of crap (block, crank, pistons, cam, lifters and pushrods) he looked everything over. He thought it looked to be in pretty darn good shape for the claimed 101k milage on it all. This week, they're gonna get measurements on everything to see what needs to be done. So within a week, I should know what needs to be done, and the approx 4-6 weeks is the ETA. They will most likely do all the machine work I need and build the motor though the pistons.

So that is my lil update as I'm very optomistic right now..... Only cause I know I'll adventually hit slow and tough times with this project.
Pete

Good first step, get an engine together.

My rebuild, this time around, was the same way have the machine shop build the short block. Was not real expensive either about $300.00 to build it up.

I see in the first message that you are using Duff's adapters, good stuff but look into the L&L products, they are really good. Life time warranty on most of the part in the kit. You get Motor Mounts, Oil Pan - modified to fit in the explorer with independent suspension, Oil Filter Relocation kit - these part are relly good machinings, and Headers - the heavyest in the industry and garrantied for life, I think that is it, but may be more. L&L parts are the best in quality and warranty.

Consider using an AOD Transmission, the first gear is a little lower which can help in either off-road or when you first take off and the OD will help on the road, especially if you regear for larger tires. The OD is controllable be the gear shift and doesn't have to be use. The AOD will cost more than the C-4 but believe me, it will be worth it. I have been using a C-4 for almost six year and I have finally come to my senses, the RPM on the street is too much. I have ordered a GER AOD should be here shortly.

Good Luck,

Ok, now my swap plans are coming of age. I found a 5.0L from a '92 mustang with harness/computer, supposedly runs. $150. I'm guessing that "150" is a typo, surely it's 1500.... anyway; I now need to find a tranny donor. I'll eventually have the tranny rebuilt, but for now i need something to get me here and there behind the v8. Loaded question: What is the best automatic transmission for me? I need decent gas mileage on the highway, strength, reliability, and gear ratios appropriate for off-roading. Help?!?

Ah ha...I have forgot one thing in my update.....
I will be keeping the T-5 manual due to funding and simplicity.... I am kinda ticked though.....This motor and tranny came from a totaled mustang....and well. the frame musta bent, and the bellhousing is cracked....Too far to be welded....So that is another thing I get to fix now....
Pete

My opinion again !
Consider using an AOD Transmission, the first gear is a little lower which can help in either off-road or when you first take off and the OD will help on the road, especially if you regear for larger tires. The OD is controllable be the gear shift and doesn't have to be use. The AOD will cost more than the C-4 but believe me, it will be worth it. I have been using a C-4 for almost six year and I have finally come to my senses, the RPM on the street is too much.

Good Luck,

Uh, maybe the AOD would be a better tranny if I were using an auto...But the AOD comes with a first gear some where around 2.46....where as the T-5 is either 2.95 or 3.35 or something around there. This will get me a better crawl ratio. Not to mention, if I went to an auto, I'd have to get the swap for that b/c my engine is setup for a manual.....this is why i am choosing to stick w/ the T-5 b/c it will be less work.......
Pete

Originally posted by RFR2212
But the AOD comes with a first gear some where around 2.46....where as the T-5 is either 2.95 or 3.35 or something around there. This will get me a better crawl ratio. Not to mention, if I went to an auto, I'd have to get the swap for that b/c my engine is setup for a manual..... b/c it will be less work.......
Pete

Pete, the auto will give you a better crawl ratio because of the converter, it effectively doubles the gearsets ratio. Won't show it that way on paper but it will on the trail.
Just go to the boneyard and get the tranny and 1356 case out of a 4x4 truck, that way you'll have a manual case also. Grab the computer and harness to the tranny also.
I think this would be easier in the end than fighting with the clutch linkage and everything else.

Todd....I shot ya a PM...though my whole attempt is to keep you as far from this project as possible;) I need very lil harassment(Yer a tough one, but a damn good guy), and I know Matt is gonna give me enough. Also, I want to do as much of this to get my hands in there and say it was my work. I gotta learn, or start to, sometime. I do understand yer lookin out for me(so I don't screw up), and I love it...But I also dont want a wild guy all over me, like ya were Riff;) Although, yer more than welcome to share thoughts, ideas, opinions......and maybe spin a few wrenches:) But, any info is appreciated....
Pete

P.S.
I call the motor shop Thurs mornin to hear what shape the motor, heads and other parts are in....lets hope for the best

OK on the T-5 setup.

Have you considered using the manual trans and T/C from an F-150. Should bolt up to a 5.0L and work more like a stocker. I am not sure what the ratios are but can't be much diff from the T-5.

How about an NV4500 w/6+ to 1 first. (A lot of money!)

Good Luck on the change over which ever way you go.

Keep the forum posted to your progress.

I just thought I'd add my weekend excursion to the thread. I picked up a mustang clutch and brake pedal assembly...It took alot of work to coax it outta the stang, but from the first look on my X...it looks very simple to swap in. Most of the bolts from the two match exactly, and the clutch hole in the firewall is already there, with only a plug in it...so that is optomistic.....I've ordered the engine rebuild kit...and total, it looks like it'll be about 1200 for the kit, machine work, and assembly of the short block....which is what I expected....So, the machine work will begin as soon as I get them the new parts, so the machining can be perfect. All my motor measurements will match stock specs of a 90 302 HO motor, except the pistons and rings will be bored .30 over, which is fine with me :) I'm busting my ass at work, to rake in all the OT possible, b/c I can use and money I can make....So, I am still optimistic about the project, and will shortly start cleaning up parts, painting, and oiling bolts under the hood to hopefully break em loose by the time the swap rolls around.....
Pete

Well, I got the motor back and it looks beautiful! Slowly, I'm rebuilding it...And with in a few weeks, I'm gonna start ordering the swap parts, seeing as the swap is less than 1 MONTH away :D
Pete

Just thought I'd let y'all know, the swap has officially begun! I started with the removal of the hood (yes I marked it for easy reinstallation)and some of the interior so I can get my clutch pedal in as well as tranny shifter and T-case shifters. Many pictures will be taken, it's all a matter of getting them online
Pete

Sounds like you have taken the first step.

Good Luck and I hope all goes well,

Well, it's sunday evening, and I've called it quits for the night. Andre came and made a huge difference on saturday! We ganked the old motor out, and started the new motor mounts. Today, I finished the mounts and with the help of my brother and friend, dropped the motor in and got it bolted down. I've got the headers in for testing purposes in, and half the accessories. More will continue tomorrow..
Pics will also arrive shortly.... Dre, got any to post?
Pete

Well, the project didn't stay on schedual as planned....But hey, it's a motor swap.... So, things wouldn't exactally be smooth as I wish.... Everything is in except fuel lines, vacuum lines, wiring the the battery, airbox and about half the computer lines. Everything else is installed waiting for it to run.

The T-5 shifter is situated some where similar to where a stock X shifter would be. It's pretty much in the middle of the removable plate on the tranny tunnel. The twin sticks for the dana 20 are gonna take a lil trimming to get them all the clearance they need.

With the dana 20 t-case, I needed to lengthen the rear shaft and the front one needed to be shortened. If there is anyone in the Chicagoland area, Suburban Driveline in Villa Park on North Ave did the work, and they're beautiful!

This project still isn't complete for one reason. Time! I ran into the beginning of school, so that quickly stopped my work on it. Early Sept. I'm gonna have a local racing shop finish it up, so then I can come back from school, and have one bad ass early X with a nice 302!

Pete

RFR2212,Looks like you have a good start to the project.

I started mine and got laid off and everything came to a stop. Toys are great but we do need to eat and live.

I removed my engine/trans, have the D44 installed except for the trackbar and finishing the bolt up of the Radius Arm brackets and the 9" is in. I have a lot completed but it has taken me almost two years to get this far. (Did not have a steady job for two + years) So things can get screwed up but I am getting back in to the project and hopefully it will get off the ground soon.

The wiring is a separate project itself; I am not looking forward to it and think it will take most of the remaining time on the project.

I do want to modify the front cross member in the near future or at least before I put the engine in but only time will tell.

Hang in there, all will come together when it comes together.

Good Luck on the project and with school.

Well, the project took a turn for the worse, when the shop that always works on my truck found the engine isn't aligned. It's sitting crooked, and basically has to be pulled to be set in properly. Translation, most of the swap has to be redone. I don't have what it costs to do this, nor do I have the time to redo it myself. So here, the project comes to a halt. It looks as though John (cableguy) will be buying what is there, and come spring time, finish this off, and have one hell of a truck. As for me, it looks like I'll strip parts that I want, and some that he won't use, and keep them for the future X. As of now, it looks like I will be purchasing Dre's X, and come spring time, add my suspension, to his already kick ass truck. So it looks like my model Sport HO, has come to and end with me. Hopefully, it will live on, one day in glory, and kick ass 306 power! And hell, maybe one day, I'll still get to take it for a spin...
Pete

hey,
I do not understand why was the engine sitting at an angle?
What motor mounts did you use?
What trans are you using?
Did you use the stock trans mount?
I would think those are the only things that could cause you a problem?

Something else must be wrong, I have never heard of any conversions having this problem.

Please get back to us here at the site to let us know what is happening.

Oh ya, what year is the vehicle?

I used the duff mounts, and mounted em according to the directions... I know the motor wasn't aligned when when i initally placed it in there. I had to twist it once the motor mounts were all loosly connected. After all the tranny was connected, to my naked eye, it looked good... I probly shoulda gotten out the ruler.... anways, it seems that the motor just needs to be yanked and one of the holes slightly largened to make clearance to shift it a little more.
Pete

Oh yeah, it's a 91, and I had to make my own tranny mount b/c of the skyjacker lift and the modified t-t (adapters and stuff)

Sorry to hear that it is ca-put in the project.
I am in almost teh same boat with my Navajo. If I could sell it I would start a new project.

Good Luck on the next one.

Well I thought I've posted some updates, but I guess I haven't.... or they got lost... anyways heres an update... I've kept the truck and tinkered on it since winter, but have been away at school. Since I've returned from school, I've taken care of a cylinder head problem, as well as the Heater Box (http://www.explorerforum.com/forums/showthread.php?s=&postid=367651#post367651)Here is the most recent pic (tonight) fer where my motor is at. I've got all the intake sitting around ready to go on, just after 11hrs of modding the heater box, and fixing the heads, I was kinda worn... So hopefully by this weekend, I'll reattach the intake, accessories, and fuel lines. This weekend I dunno that I'll work on it a ton, cause I'm gonna be doin some routine maintainance to the 94 Limited, but who knows... knowing me, I'll be back at it.

Oh, and fer anyone who hasn't seen much of this thread, I ended up with a 306, and no 336 :o

looks good!!!! interesting airbox idea, heck, whatever works

How exactly was the engine off centred or misaligned? I know that my engine isn't quite where I wanted it but I don't feel that it will cause any problems with runablity or driveablity. My engine sits at a slight angle to the drivers side by about a degree. I could shim it but I am not too concerned.

I just got my truck back from the tranny shop (no second gear in rebuilt tranny) and am amazed at how well the conversion turned out. Keep punching away at your truck, the results are worth every bloody knuckle and fight with the girlfriend because of the time you spent on the truck.

Uh, well if you were to sit in the drivers seat, the pass front corner is further to the right than the rear.... So, with in the frame rails from the front of the truck, it angles to the right... Not a huge deal, it's minimal... I think the shop made a big deal outta it b/c of possible insurance problems down the road if it fails, as well as cause the guy that runs the shop is a perfectionist... To the degree it's misallignened, it's no biggie to me and it should run just fine

RFR2212,

How did the swap turn out ?

Everything straighten out OK ?

Let the site know what is happening.

:us: :chug: :can:

hmm, The shop made the alignment problem sound like a disaster! I hate to say it, but my engine is not aligned perfect. It's close, but its visibly off. But, let me tell you, it makes no difference whatsoever. I do not have any vibrations (motor or driveline) becuase of the misalignment. Anyway, In my case the minor misalignment is not a factor.

Good Luck!

Al :D

Right... I do think he blew it outta perportion... I never got to talk with him, when the truck was in front of him, b/c I was away at school, so it was all phone conversation... I do think I will be fine.. The swap is still in progress, and progressing slowly.. I might slow up some the next 2 weeks cause im broke waiting fer my first check since I've gotten back, so I'm gonna only do minor work with what I've got till I get money... The only thing I'm saying now is running before the end of the summer, and I'd prefer to get some miles on the motor and get it good and broken in... I think it's possible... I'm not as stressed for time like I was last year, and I'm further, know more, and a weee bit more patient now :) The patience will persist, and like my grandfather who taught me alot of hands on stuff said "Never let an inadimant object beat you" So I'm telling myself, and truck, that this time i will win! Whether it likes it er not :)

tear rolls down my eye........
Keep up with it Pete......it'll be bad ass when its done!
I was once thinking about selling out at one point. Glad I didnt though.

Al

Oh, it'll run damnit! This truck won't win! Oh, goin to the post office tomorrow mornin ;)

RFR2212,

Good Luck don't let the truck win.

Perseverance pays off, you will love it when completed.

Ford should have built the "X"s with a 5.0L. This engine makes the vehicle a completely different animal.


:us: :chug: :can:

Originally posted by RFR2212
The patience will persist, and like my grandfather who taught me alot of hands on stuff said "Never let an inadimant object beat you" So I'm telling myself, and truck, that this time i will win! Whether it likes it er not :)


http://www.explorerforum.com/forums/showthread.php?s=&postid=493665#post493665

Here's the continuation to the project... Check it out, someday it's gonna be done! Still workin on it! :rolleyes: :cool:
Pete

Taken a turn for the worst, ehh?

Hey Man, good to hear you are still working on it.

I sold my Navajo and have started the next project.

A guy walk into my garage and offered me more than I could refuse, he trailered the Navajo away, but didn't buy the D44/9" axle combo, now I have an axle set to sell.

Good Luck, keep it going.