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1997 Ford Explorer - V8 - 5.0 - AWD

Discussion in 'Stock 1995 - 2001 Explorers' started by Spudhut, November 21, 2017.

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    Should I pick this up?

    1. Yes

      5 vote(s)
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    2. No - Its junk

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    1. Spudhut

      Spudhut US Navy Submariner Elite Explorer

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      Year, Model & Trim Level:
      1997 Explorer Sport - 4x4
      Callsign:
      KG5SPB
      I decided to pull the spark plugs to inspect them. (Cyl 7&8) I stopped here - I'm sure the rest are the same.

      They are Motorcraft Platinum.

      Seriously, I don't think they were ever changed. They have a gap that's almost 1/8" wide.:eek: (they were normal black on the ends, I used a wire wheel to clean them off) New plugs are on the way!

      [​IMG]
       
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    3. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      Great, know you've moved closer to knowing it's solid again. I'm glad they came out easily, sometimes being so old they don't.
       
    4. Spudhut

      Spudhut US Navy Submariner Elite Explorer

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      1997 Explorer Sport - 4x4
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      KG5SPB
      Did more work on the Ex last night.

      So I found an Ohm test for the IAC. You can do an ohm check on the unit to verify its "good". However, I did pull it off and clean the inside out; there was only a little carbon build up. Grab a multimeter and put on Ohms setting. You want to be in the range of 7 - 14 ohms. Mine came in at 9.4 ohms. Just for kicks, i went to my local 'Pick-n-Pull' and tested a few on their cars and they all came in the same range.

      I picked up some new plugs so I can swap out the old ones. What a bear to get to them - especially through the fender well. Thankfully they came out easily. These are placed in their respective cylinders (top of picture is front of engine). A few had gaps as large as .70. The tips on the electrodes were quite burned.

      [​IMG]

      Glad I did the plugs. Its nice to run into other 'hidden' issues when doing other tasks. I found #4 wire barely connected at the boot; electrode hanging out of the insulation. Thankfully I have new wires on the way! Could be the main reason for the slight 'lumpiness' in how the engine runs.

      [​IMG]

      I have been researching on why the blower motor only works on High speed setting, and why the fan is possibly turning in the opposite direction. There is little to no air moving throughout the system. I picked up another fan switch hoping that would be the fix, but I was wrong. Through my research, I was reminded about the blower motor control module. It's located under the fan housing in the engine bay (passenger side rear corner) so I pulled it out using an 8mm socket to inspect it. Not good. Even the connector was tough to pull off due to corrosion. These don't have a gasket on them and a lot of this rust comes from condensation collected in the heater box over time. If your fan isn't working properly, its a good sign that the diode in this resistor is blown. Now, don't be mistaken, I picked up a unit from a random Gen2 Explorer thinking it would work. There are 2 different types available. You have a 'Manual' type and an 'Automatic Temp Control' type unit.

      This one pictured below is the 'manual' type.
      [​IMG]

      Automatic Temperature Control
      [​IMG]
       
    5. 1998Exp

      1998Exp Active Member

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      In the photo of the manual (resistor-type) unit, the pointed component is not a diode. It's a thermal fuse, designed to disconnect the current if there is no airflow (due to stuck rotor in the blower, usually).
       
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    6. Spudhut

      Spudhut US Navy Submariner Elite Explorer

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      Thanks @1998Exp for the clarification, that makes sense
       
    7. Spudhut

      Spudhut US Navy Submariner Elite Explorer

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      I picked up another Blower Fan Resistor and installed it. To confirm, that was my speed issue. I figured I would clean the fan blades as well, so I pulled the fan out since I had the room and I found a heater box full of acorns...LOL. This is after I cleaned it.

      [​IMG]

      Even though I replaced the resistor (grey connector in lower right of photo), the fan speed is a bit off. Its another used part in good non-rusted condition. The fan changed speeds but compared to my Sport heater fan, its seem slower and the air flow is a lot less. I'm going to swap fans with Sport to see if there is any change/difference.
       
    8. Spudhut

      Spudhut US Navy Submariner Elite Explorer

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      1997 Explorer Sport - 4x4
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      My cruise control switches were basically trashed - (bad material design i suppose) found some good ones at JY and replaced.

      Old Units:
      [​IMG]

      "New" switches
      [​IMG]
       
    9. Spudhut

      Spudhut US Navy Submariner Elite Explorer

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      For anyone following: I did a quick tune up on the engine. I installed new spark plugs, new plug wires, air cleaner and checked the connections on the motor. Fired it up and the motor purrs nicely. It did have a little trouble initially starting, but ill investigate that further. I plan on doing a PCV and Hose change just to make sure its breathing good.

      I took it for a test drive and it felt strong. The trans however seemed to shift good. It certainly has different shift points than a 4.0/Sport model.
       
    10. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      Very good. Now run some fuel injector cleaner through it a couple of times, and clean the IAC if it hasn't been done before, and enjoy it.
       
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    11. 97-5.0

      97-5.0 Member

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      City, State:
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      Year, Model & Trim Level:
      1997 5.0 AWD
      Trust me, do a transmission fluid change,
      Unhook the cooler line and start car- stop when bubbles come out of line, then
      drain the torque converter - round black 3 inch rubber plug at bottom of transmission, inside there is the TC -turn engine by hand untill the drain plug shows up - factory TC has drain
      Pull pan and change filter - optional - do it ;)
      Fill 6L then start for 2-3 seconds then Off
      Fill 6L then run for 2-3 then off
      Your filling the TC with fluid
      Top it up, start and shift thru every gear "foot on break", getting air out of system
      Check level at idle, level ground, add if needed,
      Don't forget the cooler line!

      Sorry don't know how many L.
      Do it again when you feel the transmission get weaker, over a year depending how hard you drive, a new filter Will last Year's+
       
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    12. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      I would expect that owning a new vehicle suggests changing all fluids and filters. I did it all with my new 98 last year. The 302 trans takes 12+ quarts of ATF. I added a deep pan and ended up using about 15 quarts, but that's from empty(I had the VB off also for a couple hours). There's a couple of quarts trapped above the VB in all automatics, so loosening that drains a lot more.
       
    13. Spudhut

      Spudhut US Navy Submariner Elite Explorer

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      Thanks Guys!
       
    14. Spudhut

      Spudhut US Navy Submariner Elite Explorer

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      Been a good day. Took 1/2 day off from work and pulled this 4406 TC this morning with the stick, boot, shifter, cover plate...everything. 20 degree's out here...gotta love the dedication to the hobby!

      Ill need to go back again for the driveshafts.

      There were 4 more trucks out there with 4406's and shifters out there. (98' and up)

      [​IMG]
       
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    15. Spudhut

      Spudhut US Navy Submariner Elite Explorer

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      What are the cast manifolds on typically?
       
    16. WhiteLX

      WhiteLX New Member

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      99-01
       
    17. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      You have the GT40 heads(96-97.5 302), so the later GT40P head manifolds won't work for you.
       
    18. Spudhut

      Spudhut US Navy Submariner Elite Explorer

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      Bummer!
       
    19. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      Good job on the BW4406, I wish I had the motivation to go get another one. I'd like one of those shields to that seem to only come on the manual version, that plastic piece over the front output.
       
    20. Spudhut

      Spudhut US Navy Submariner Elite Explorer

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      If your referring to the round cover over the the front output it's metal. :thumbsup:

      @CDW6212R - next time I go out there, Ill keep my open for one and pull it for you.
       
    21. Turdle

      Turdle I bake stuff Staff Member Moderator Elite Explorer

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    22. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      Thanks, no rush, just another item of my long JY list. It should be enjoyable to go to a JY if you can do it in decent weather with no stress. My friend and I try to go a couple of times a year, even just to look around and see old cars we liked.

      I assumed you have an early 97 from the glimpse I saw of your EGR elbow. The top of the elbow on GT40 302's is perfectly flat, while GT40P 302's has a curved top, and the EGR pipe going to the manifold below.
       
    23. Spudhut

      Spudhut US Navy Submariner Elite Explorer

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      MFD Date: 08/96

      Early build...im sure is limited for add-ons?

      There's a U-Pull-It next town over from my house and minutes from my work (same one). I like to go there on my lunch break and look through all the Explorers and other cars, pulling all the good stuff (especially Add-on's I can put on my Ex). I read the forums at work so I get lots of ideas! ;)
       
      Last edited: December 7, 2017
    24. Spudhut

      Spudhut US Navy Submariner Elite Explorer

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      Quick Update - Now that I got it running good. I started collecting parts for my SAS - Coil buckets and truss for XJ D30 are finally in hand. 7" ZJ Coil springs are on the way by recommendation by @2TimingTom. Going to pull Ford Steering box this weekend and Heims/brackets/Tubing are sourced, just waiting on funds.:bounce:

      Having used forums for many years - I understand searching for info, but I'm having a heck of a time looking for some 3 link information. I have tried Pirate4x4 and this site, but to no avail cant find much 'useful' info/pictures (Photobucket isnt helping much either). Plus, on the other hand, there is so much info - especially on Pirate4x4, it gets so convoluted; my brain hurts. I realize its not rocket science. I have downloaded 3&4 link calculators, looked at graphs...Info for other trucks....OMG! :confused:

      I'm not looking to build a rock climbing rig. I will be driving on the street and off-road. Maybe some hill climbing, respectable flex abilities but nothing extreme. If anyone has a link to some 'pre-designed' information (angles and measurements and photos too!) for these trucks that I can follow and use as a rule of thumb; that would be helpful.

      Thanks! :feedback:
       
    25. 96eb96

      96eb96 Well-Known Member

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      96 EB V6 OHV 4WD
      For the 97 4R70W Trans, when you drop the trans pan:
      Replace the 1-2 accumulator and spring. Just comes out with snap ring pliers, support the accumulator so it don't pop.

      Perform this TSB if you plan on keeping it:

      http://www.idmsvcs.com/2vmod/tranny/accumulators/tsb971111.pdf

      It is also critical you have a clean fill of Mercon V. Nothing else. Pump it out the cooler as others said.
       
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    26. fastpakr

      fastpakr Elite Explorer

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      Do you know if there are any TSB's for the later 4R70W's? I haven't done very well in looking that up.
       

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