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supercharged 5.0 true fire 98 explorer sport

hi everyone, my name is tim . i live in selkirk, manitoba, canada and as if this date that i am posting this, i am 36 years old.

i bought my sport in jan 05 from a local ford dealer. it had 111,000KM's on it. this is the second sport i have owned. it was sitting on the lot for about 8 months before i came along. i am the third owner (i was able to track down the person that traded it in, and they got it from a friend, who bought it new in 98).

i started to do a few things to it after i first got it, then i found this site, and all hell broke lose! i've never been satisfied with something the everyone else has, so i started to tinker with it even more.

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mods include

interior

installed factory tilt, cruise, overhead console, auto dimming mirror, full length console, with a message center (it didn't have these from factory).

white face with blue flames indigo gauge covers (they light up blue)
blue l.e.d. everything
white l.e.d. interior lights
Kenwood DDX392 Touch Screen Head Unit
alpine 4 channel amp (all four speakers)
boston acoustic front and rear speakers
alpine mono amp (for sub)
2 12 inch jl audio subs
rockford fosgate cap
passenger side one touch window down mod.
custom transfer case shifter
tripple a pillar gauge pod, housing autometer boost, Innovate LC-1 wideband, and oil pressure gauge
12v power inverter with 120v plug in a 2 usb plugs built into the center console

exterior

BMW E46 projectors, mounted into stock housings using clear lens
6000K HID head lights
angel eye "driving" lights, with 8000k h.i.d.'s
clear parking/corner lights
billet grill (powder coated by Turdle)
blacked out ford emblems
custom front steel 95-98 bumper, with 4 inch round tubes welded in for driving lights
shaved radio antenna
shaved roof rack
black euro tall lights
l.e.d. license plate lights
smoked out 3rd break light
lund rear tailgate spoiler/wing (formally from the truck "blackjack" owned by EF member Spas)
hand made roll pan (made from 3 1/2 rear bumpers, with 1/4 inch diamond plate on the top, and it is removable)
aluminum T/A differential griddle/cover (powder coated by Turdle)
Motegi Mr107 20' rims
goodyear wrangler hp p245/50 r20
1 1/4 wheel spacer in the rear, 3/8 in front
and most noticeable, black with blue pearl paint, and blue true fire (ground effects are black with blue pearl as well)

Suspension

2 inch lowering blocks in the rear, reverse TT in the front (2 inch as well)
Explorer Express rear sway bar
4 door leaf springs
rancho rs9000 adjustable rear shocks
03-05 sport trac spindles with drilled and slotted rotors

performance

5L swap
347 stroker
TFS twisted wedge alum heads
comp gold 1.6 rockers
comp cams CCA-35-556-8 nitro cam
heavily modified edelbrock victor jr air gap intake (which serves as a valley pan now)
eaton m122 supercharger (metco 2.70 pulley, and ASP 8 rib 7 1/4 crank pulley) with custom made mount with bell intercooler core
8 rib serpentine belt conversion using pulleys from a 7.3 powerstroke
custom made 3 1/2 inch throttle body elbow
accufab 75mm throttle body
4 inch intake pipe
PMASS MH90 90mm Universal 3000 KG/HR MAF
amsoil cone filter
F.A.S.T. 60lb injectors
edelbrock fuel rails, trick flow specialties fuel pressure regulator with summit racing fuel pressure gauge
walbro 255lph fuel pump
1/2 inch steel braided fuel pressure line from tank to rail using 8AN fittings
torque monster headers
2 1/2 duel pipes with flowpro duel in and out 2 1/2 single muffler
accel extreme 9000 ceramic 45 degree plug wires with boot protectors
4R70W w/2600 stall with J mod
tuff stuff 200a alternator
tuning made possible with sct pro-racer package, and tuned with major help from member [MENTION=102869]Dono[/MENTION] and [MENTION=81804]4pointslow[/MENTION]
flex a lite duel 12 inch electric fans
big 3 upgrade (4 gauge wires)
meziere innercooler water pump
2 froozenboost innercooler rads

Transfer case

4406 manual shift from a 97 F150
modified stock trans cross member to accept 93 mustang 5L polyurethane tans mount
double cardan rear drive shaft

because of all the "fun" i had doing the bodywork, and some other things to my truck, i have nick named it "evil dora" or if you like, just plane "evil"!
and now the thank yous

my buddy gord leiss, who let this thing sit in his garage for 3 months while i did the body work to it. he also gave me a hand with some of the prep work, and painted it for me

kevin willson for doing the true fire http://affordableairbrushing.ca/

Joe Bukoski for letting me do the 5L/4406 swap in his garage

now people from this site, weather they knew it or not, they helped

BIG THANKS to tara a.k.a. explorersport77 for pictures of her truck. wouldn't been able to build the roll pan with out them!

ExplorerSport77's X "Hotness"

jon a.k.a. Turdle for selling me some real swanky rear shackles, as well as powder coating the diff cover and sending them up to canada. as well as much needed info on v8, and 4406 swaps as well as doing the grill and showing me how its done.

don aka dono for the help with the tuning, and wideband, as well as the supercharger

andy aka ahodges for some parts, and any help i needed for all the go faster goodies

5.0 swap - w/ 4406

jad2411 for finding me a link for my hidden antenna

ryan a.k.a. MustangP51 for doing his write up on making l.e.d.'s for interior lights, and how to make projectors

P51's HID Headlight (Projector) and Fog Conversion (PICS)

and N3ELZ cardomain page for L.E.D. switch and cruise pod mods

http://www.cardomain.com/ride/296394/2002-ford-ranger-regular-cab/page-6
http://www.cardomain.com/ride/296394/2002-ford-ranger-regular-cab/page-12
http://www.cardomain.com/ride/296394/2002-ford-ranger-regular-cab/page-23

bob a.k.a. rwenzing for showing me speedhut's sit for the gauges

Gauges, Custom Gauges, Tachometers, Speedometers, Shift Light, Pod

Buzz4x4 for his write up on blacking out ford emblems

How to Make Your Own Custom Ford Emblems

the late aldive for his write up on one touch down passengers window mod

http://www.explorerforum.com/forums/showthread.php?t=141027&highlight=touch+passengers+window+mod

BIG COUNTRY, for his write up on how to install a auto dimming mirror

http://www.explorerforum.com/forums/showthread.php?s=&threadid=84968

BIG COUNTRY, 98formulaLS1, and Ryon40 for there write ups on how to install a message center

http://www.explorerforum.com/forums/showthread.php?t=225017&highlight=BIG+COUNTRY
http://www.explorerforum.com/forums/showthread.php?t=80670&highlight=message+center
http://www.explorerforum.com/forums/showthread.php?t=245085&highlight=Ryon40

MountaineerGreen for his 4406 swap write up and "Custom" Driveshaft for a 4406 and 4" Superlift on the Cheap " (even tho its lowered

http://www.explorerforum.com/forums/showthread.php?t=166726&highlight=awd+4x4+swap
http://www.explorerforum.com/forums/showthread.php?t=185232

Simon, aka blueka for his "pickle" thread, and help anytime i picked the phone up the phone on the 5L swap

http://www.explorerforum.com/forums/showthread.php?t=271813

Jon, aka 4pointslow for any MAJOR technical advice i have needed

http://www.explorerforum.com/forums/showthread.php?t=219092

i wish i could find who did the write up on the overhead console install, but here is the link

http://www.explorer4x4.com/overhead.htm

Russ aka NICE59FORDF100 for his help on the wiring, and what to watch out for electronically.

hopefully one day, i will be able to help people on here just as much as the people that i have mentioned above!

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plus you know you have done something right when.....

your truck (as well as corkey) wins truck of the month

http://www.explorerforum.com/forums//showthread.php?t=296023

is the feature truck on the fun hump day radio show (starts roughly around the 30 min mark)

http://explorerforum.podbean.com/2011/03/23/19-vroom-zoomboom/

and you drive 26 hours ONE WAY to the carlisle all ford nationals in june 2010 and 2011, and grab second place in the s.u.v. all category!

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then in 2014 you go back to the same show you have been to 5 years in a row (nothing by most, but its one hell of a long drive) and take first!

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Wow good stuff!
 



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Very good Tim, now you will hopefully have found a good builder for the TC. You want strong clutches in it for the high power, and the heavy truck. The stall speed is an art that they need all information about the vehicle to get it close.

Hopefully you got a good feel for your last engine/trans/TC combo, and the new one even though it didn't live long. Be slow and deliberate when describing to them when it stalled, were you believe it began pulling from an idle etc. Given the right input for those things with the two combos, they should be able to make the stall close to where you tell them you want it. Take them the previous converter also if it wasn't completely stock, and even if it was stock it might help them to pin down what to make the new stall at. Good luck,
 






buddy had time today to pull the trans apart. the good news is there isnt really and damage. only one thing is the sun shell has some wear groves in it, but thats not a big deal.





so he's going to make list of things needed, and get them ordered. i am hoping maybe by the end of the week, if not next week it will be done. so we will have to say a bad pump gear and worn converter hub was the problem.....to bad i had to find out the hard way instead of doing what i normally do with stuff like this and pull it apart from the beginning and check it out before i put it in.

i also discovered evil was trying to kill me



that there is my fuel pressure line. you know, the one that is near the really hot header? ever since i put the fuel rails in i could smell gas but couldnt find from where until now. yea, that got changed fast.
 






That second pic kinda makes me go cross-eye'd.
Maybe Evil's trying to get back at you for gutting her so many times.
 






I had to replace the rear line in my Mountaineer this Winter, it was bad at the fuel pump from past connector fights.

How do you like that trans jack Tim?

I just bought one like it from HF to do my trans of my V6 truck.
 






before i give evils update, i want to say a few words.
Thursday april 23, the forum, as well as people that knew him (i included) lost a friend. Chris Mercer (aka [MENTION=5923]Skunk[/MENTION]) suddenly past away at his home in freeland, pa. he leaves lindsy (aka [MENTION=6507]Spas[/MENTION]) to mourn him. i did get to meet him every time i went out to all ford nationals, and hang out with him. he was a avid 4 wheeler if on his quad or his truck skunk. he had a pretty keen sense of humor, and could take a joke just as good as he could throw one back at you.







rest in peace chris, you will be missed.



i picked the motor up from the machine shop on friday. i had to light a little fire under there ass because they had the motor for over a month, and i kinda wanna drive it this summer.

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i started putting it back together, but my heart really wasnt into it as much as i tried. i got to putting the cam, chain, front cover and heads on and called it.

the massive thrust bearing they put into it

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went back at it today, and just so nobody freaks out like the last time



i also bought a oil pressure gauge for it so i can watch it destroy itself in real time, and not have to guess if it is or not. note, if you do buy one for the v8 motors, you will need to get a 45 degree fitting for it. the bell will not clear the block

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gave my son a call, and he came over and helped with putting it back in. i really want to teach him some of this stuff so he will know how to work on anything he may buy for himself. that and i think he wants to take evil for a scream because he has his beginners. i might.....maybe......

and [MENTION=102869]Dono[/MENTION], i think i may have found a spot for a knock sensor that i never noticed before. then again who knows what this block came out of.

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just waiting on the trans, which is a whole new story that i am not getting into. that should be done i am thinking monday hopefully. i want this thing running before the weekend!
 






Holy crap Tim, I didn't know you were dropping the motor in today. It's probably better you spent some quality time with your son, than me. :)
Great to hear your over the hump and starting to put it all back together (again).
 






Looks good Tim, fingers crossed for it to be smooth sailing this time.


God Bless you Chris Mercer, and all of your family and friends.
 






In there!

Wow, the engine is sitting back in there already! Great progress!

If you can mount the knock sensor you can add a J&S Safeguard device like the Vampire (or something else) for added protection against detonation.

Something interesting about oil pressure,
I have some information stating thrust bearing and rod bearing failure will not cause low oil pressure. I believe it goes like this, since the thrust is lubed with run off oil from the mains and the rod bearings are last on the oil circuit after the mains they don't usually cause low pressure.
Main bearing failure will cause low oil pressure.

Hope the rest of the re-install goes as planned!
 






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she's whole again. i got the trans back from my buddy late tuesday night. wednesday i put it in, and what a circus act that was.. i also had to call a buddy to help me with the transfer case (andy, i have no idea how you did that by yourself, but i have new found respect for you!). i was outside till around 11 o'clock. hey it was nice out! all i had left was the driveshafts, starter, supercharger and some other small things. got it hooked up, and fired it. i immediately could tell there was something off with either the timing (even after marking the balancer) or fire order (and after marking the wires). i was just about to start digging into it when....it started raining.....figures. i have been waiting how long, and i am this close, and have to stop.
so if it isnt raining tomorrow i will dig back into it.
 






Weather

The weather has been awfully inconvenient so far this year. lol.

You will have it back together soon, and it will be kicking a** and taking names later!
 












Awesome! That is so frustrating when you get to the finish line but can't cross it.
I got my transfer case in by myself with the help of my friend the floor jack, and installing some nice scratches in my blue paint...
 






i cant make this up if i tried....
for the pass couple of days i have had a hell of a time getting evil to run right, and seemed no matter what i did, it would not start and say running. today my neighbors little guy came home with some toy tools. i told him he should come by and help me fix the truck (he loves evil btw and refers to evil as "loud truck").





right after that i figure i want to try it one more time. well, i dont know what kind of magic that kid did, but it started and idled.....WFT, and i never touched anything!
i ran it for about 5 mins, then i noticed it was dangerously close to overheating. in my excitement i forgot to leave the rad cap on the first catch if you want to call it that.



can you say air lock? after i rain away from it for a few mins because it was gurgling like nobodys business i loosen the cap, and air lock was gone. put some more coolant in and fired it up. this time i heard the fans kick in, so that was also good to.
it still didnt sound right, and i have around 3 pounds of vacuum. why so little, i have no clue yet. buddy came over and we also found #6 cyl is a dead hole right now (which will explain why it didnt sound right). another thing we also discovered is the cam sensor lock tool has something like 20 degrees play. in the morning i am going to try a different plug wire and see if that fixes the dead cylinder. i am also hoping that will solve my vacuum problem. this never ends i swear...
 






<-------dumb guy! went and decided to do a compression test on #6 , well....it was ZERO! at first i thought the gauge was broken till i covered the hole with my finger while my son bumped the motor. i could have farted harder then the compression. so off came the valve cover, and every valve got looked over on that bank. readjusted #6 , and like magic i had compression.....but still no vacuum. pulled the blower off to check all the fittings, and ever epoxied around them just to make sure there was no leakage, and hose clamped all the hoses as well. then put it all back together...nothing. clamped the brake booster vacuum line in case it was leaking internally and couldnt hear it....nothing. so once again, this thing is starting to drive me nuts. spent pretty much all afternoon chasing my tail. 4point is going to check a datalog that i am going to send to him tomorrow to see if i am missing something or not. hopefully it works because i am getting sick of working on this thing, and its getting closer and closer to make me really want to beat on this thing IF i get it running right again.
 






Wow, the only thing I can think of off hand to cause very low vacuum would be the pcv valve hose missing from the lower intake port. A smaller "leaking" hose would not drop it that much.

Which port are you using for vacuum check?
 






Funny you say that because the first thing I checked or is that PCV valve and it was in the intake . I am going off of my boost vacuum gauge. when I press the brakes they feel like they are a manual breaks
 






And the PCV valve isn't old. It's maybe 6 months old with very little miles
 






Ok, stupid newbie question time

Could this larger supercharger with pulley be making boost at idle which would overcome the vacuum? Did anything change up there since your other engine?

Could there be a protective film (tape) still stuck on the lower intake?
 



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See this is what I can't figure out. Other then bigger injectors (42 to 60), adding a meth kit and putting on a electric fan, everything is the same
 






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