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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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Another silly comment to add.

The one way booster vac check valve, is it working correctly?

Is the vac tree intact? I can see it being damaged by accident while installing stuff. :dunno:
 



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you mean the bypass valve on the supercharger? if so, yes its working. there really isnt any vacuum trees. i had to screw in a few brass fittings to the back of the supercharger for my vacuum lines.
fast rundown so far of what i have tried. blocked off egr, pulled vac line and blocked it off going to the brake booster. checked compression, cam has been installed straight up. checked lines, they are all new, or less then a year old, same with pcv valve. wanted to try and block that off, but couldnt reach it to unplug it.
the dumb thing is when you pull the line going to the brake booster it feels like theres lots of vacuum, but when you put your foot on the brake peddle its like you have manual brakes, and the gauge backs that up as well.
 












The valve on the "brake" booster vac line is what I am meaning. It's a one way valve. If it is cracked/bad, you could have a leak, and the brakes wont have power as you say.

I keep forgetting the 5.0 vac set up is a bit diff then the 4.0, and the vac lines are ran diff. Whoops...
 






jon, i put a pair of vise grips on the vacuum line, and pulled it off the booster and didnt see a change. i will try it again, but use something to block it with.
greg, i never did swap the booster when i put the v8 in. its a 4L SOHC booster in it still.
 






There is nothing left of 'stock' vacuum routing on Tims motor. I would really think that you would hear such a big vacuum leak. You don't.
My first guess was EGR, but that's capped and sealed tight. The vac bypass on the supercharger shouldn't stop the manifold from showing vacuum even if its not working.
Something between the throttle body and the top of the block is letting air in

I really think the leak is something internal. We should be able to hear the leak if its external. Tim, why didn't we think to go to my truck and pull the brake booster vacuum line and feel the vacuum? duh. Hindsight is 20/20.

Tim has his larger injectors in there now, but can't really start the tuning process until the leak is found.

On a side note, I can't believe how loud Tims truck is with that new motor. I see a different style muffler , or an addition of some kind in the future.

Now, what else is there that can cause an internal vacuum leak?
 






On a side note, I can't believe how loud Tims truck is with that new motor. I see a different style muffler , or an addition of some kind in the future.

strait pipes! yea, it differently got loud. as for yours....yeeep. double duho! i bumped into my son and asked him to come over tomorrow and watch the gauge for me. i am going to pinch the pcv valve with pliers and do the same again with the booster. i am also hoping 4pointslow has seen the datalog. that to might show where it is
 












been there, done that to! lol lowest was 170 highest was 180. i have been on the phone with 4pointslow. tomorrow i am going to take a close look at the pcv valve to start by pinching the line going into it. if vacuum goes up then the valve is bad. if thats not it, i am going to somehow have to pull it out and see if its sucking air into the gourmet. if it is, then the intake gaskets are leaking for some reason.
 






tried again today. pinched the line going to the pcv valve. no change. pinched the line to the booster. no change. i was lucky and was able to get to the pcv valve and pull it out while the truck was running. no vacuum going into the hole where the pcv goes.
 






Do you only have 1 PCV valve? Do you have a breather hose from one of the valve covers to your intake piping after the MAF?
 






its kinda like yours. i have a pcv valve on the passengers side valve cover that vents into the intake tube between the throttle body and maf
 






There should be very strong vacuum at that hose. The hole is where the vacuum goes to.

Unless the supercharger is causing positive pressure in the intake.

Frankly, it sounds like something is clogging the intake, like tape over the lower intake ports to keep stuff from falling in there.
 






Is it still missing on #6 ?
 






jon, i had only used tape on the inside of the mount after i put it on (and did forget to take it off so the supercharger came off for that before i even finished bolting it down). other then that, i never needed to use any. i covered things up with bags if it sat overnight. as for the supercharger causing positive pressure, i dont know how it would do that unless it was spinning backwards. donno, just asking. it this point i am not going to rule out too much as of yet.
andy the miss was because i did the valve wrong on that cylinder. we found that out using a temperature gun pointed at the header (it was about 100 degrees colder then the rest), and doing a compression test. i have readjusted it, and it is firing on all 8 now.
for giggles, i even just put a new pcv in it, and it didnt change anything
 






Do your heater controls work? Also im not sure how your vaccum line is setup for the evap but when mine split open I had a hell of a time figuring out what was wrong and it gave no codes
 






if i knew how to draw out how i have my lines, i would post a pic of it to show how i have them. i will check on the evap tomorrow and see. havent tried the heater controls yet. my one buddy is starting to think i keyed the cam wrong. god i hope thats not it. i did also talk to james henson today, and he is going to send me a updated tune in the morning so i get get it to run with the injectors i have in it now.
 






if it has compression it's getting air from somewhere,,
you also said it runs,, so it gets enough for that too,, have you tried taking off the intake pipe to the air filter and putting your hand over it while it's idling to see how much vacuum pull there actually is ?
has to be something simple, could be one of the reasons it wouldn't run before,,

You don't miss much when it comes to this stuff, so it has to be something small,
 






You have the PCV valve hole plugged with something on the back of the GT40 intake right?

List of places the vacuum line run:
PCV valve in valve cover
PCV valve at rear of intake manifold
Brake booster
EGR valve
Vacuum reservoir for heater controls
Fuel pressure regulator

I think that's it... If all of those are sealed then it has to be internal. Is it running lumpier than it did the first time around?
 



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Injectors

After you get the tune corrected for the new injectors send me another datalog at Idle and 2000. They can be on the same datalog. About 10 seconds of each. Engine at operating temperature.

Do you have the brake booster attached to a vacuum port that is pre blower or post blower. also the boost gauge and fuel pressure regulator should be only things post(after) blower. If it is set up that way then at least you know they are in the right places.

Is the supercharger bypass being held fully open at Idle and does it close when the throttle is blipped.

Edit; I had open and closed backwards.
 






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