Engine swap "Cummin" soon

*snoranger* · 07-03-2011, 04:33 AM

The time has come for another engine swap in my '95 4 door 4x4.

The previous swap (SOHC/EEC-IV) isnt having problems, but the gas mileage is poor (15 MPG average over the past year).

Here's the patient (95 4 door 4x4):

And its soon to be replaced heart ('01 SOHC):

So, you may be saying to yourself, "oh boy, another 5.0l swap." The thought had crossed my mind. I have a 94 Cobra, that could use a bigger engine. Here's the 5.0 Cobra engine that could be used:

But this is my daily driver and needs to get good mileage. I work 35 miles from home. Thats 70 miles a day, 5 days a week, 50 weeks a year (2 weeks vacation) 17,500 miles a year just to get to work. Since I'm running the SOHC on the 95 EEC-IV computer, the higher compression requires me to run 93 octane.

Lets do some simple math:
20,000 miles
15 MPG
$3.75 a gallon (checked the price today on my way home)

Thats $5000 a year in fuel.

What can i swap in that makes power, get good mileage, and will last a few years you ask?

Thats right folks.... Its a Cummins 4bt!
An 84K mile,
105 HP,
265 ft-lb
3.9l turbo diesel.

She's a little rusty and the turbos got some play, but for $1200... not bad.

It also came with a Neon SRT4 intercooler and an aftermarket header.

She's clean inside!

*snoranger* · 07-03-2011, 05:06 AM

Now, you may be saying that diesel fuel is more expensive, it will cost more to run. Most fuel estimates for this engine in a smaller truck or SUV seem to be in the 30 - 35 MPG range.

Lets take that previous number of 20K miles a year.
20,000 miles
30 MPG
$3.80 per gallon (checked today)

That works out to $2533 a year in fuel costs. Quite a bit of savings.

Now lets put all that stuff behind us and get down to the big question. Will a 750 lb, 4cyl engine fit in a 95 Explorer at stock height (or close to it) and still retain 4WD?
Good question, let see.

Looks like I will have to mod the oil pan, and make some more room for the starter. Nothing too bad. Height looks good...the hood will close. As it sits is 1/2" higher then the SOHC. So after the oil pan mods, I should be able to drop it down 2" or so. That will put the top of engine about 20 1/2" above the frame rails.
I still have to get some exact measurements front to back. Best estimate is that I'll have about 3" of clearance between the elec fan and the front of the engine.

I'm going to get some before and after weights, we have a scale at work, just have to wait till Tuesday.

*2000StreetRod* · 07-03-2011, 08:00 AM

You are planning an interesting swap. What transmission are you considering?

*BrianDye* · 07-03-2011, 08:08 AM

!!!

*snoranger* · 07-03-2011, 09:26 AM

Quote:

Originally Posted by 2000StreetRod

You are planning an interesting swap. What transmission are you considering?

Sorry, no picks of the trans. I have a small block ZF S-542 from a F350 that i picked up a few years ago for $75.
I do have to thank Karl (kbabiak) for these though:

**Tbars4** · 07-03-2011, 10:08 AM

..Subscribing...

NHarris · 07-03-2011, 07:32 PM

Subscribing to this.

Jarubell · 07-03-2011, 08:41 PM

Subscribing to this too!

Ranger379 · 07-03-2011, 09:31 PM

subscribing also!

*snoranger* · 07-03-2011, 11:45 PM

I ordered some parts.

-AC/ alt mounting bracket....$45 used. (yes, I'm planning to run A/C)
-Turbo rebuild kit.... $40
-Motor mounts... 13.44 (for both!)
-trans mount... $13.87

I also dug out some other parts:

-Sanden SD7 A/C compressor.... NIB $48.56 shipped (I bought 2 of these a while ago for an OBA setup I built.)
-Flex-a-lite 1st/2nd gen Ranger fan...... $??? no clue. (I bought it new years ago, it didnt fit my 90 4.0l w/ heavy duty cooling. i'll put it too good use now.)

Hitchhikingmike · 07-04-2011, 12:48 AM

Subscribed!

*ghosttrain2* · 07-04-2011, 09:55 AM

Subscribing

*blueka* · 07-04-2011, 05:16 PM

subscribing.. very interested in doing this in the future....

Si

*The Electrician* · 07-04-2011, 05:24 PM

subscribing, inserted to see how would you end it

*snoranger* · 07-06-2011, 01:07 PM

Little update:

Pyrometer ordered. I'll have it thursday.

Talked to the warehouse today. I'm taking the truck over to get weighed later today.

** If anyone in the area has a used steering rack (good or bad) they can let me use to mock this up, let me know.**

*albi1cnobi1* · 07-06-2011, 01:43 PM

Holy crap, man! I just found this thread, you are an industrious little bugger aren't you. I'll check my shed for the steering rack. I used to have one but I have a feeling it may have been scrapped in a previous shed clean out. I'll let you know.

*snoranger* · 07-06-2011, 01:54 PM

Quote:

Originally Posted by albi1cnobi1

Holy crap, man! I just found this thread, you are an industrious little bugger aren't you. I'll check my shed for the steering rack. I used to have one but I have a feeling it may have been scrapped in a previous shed clean out. I'll let you know.

What else am i gonna do? Sit in my recliner and watch Family Guy? Its not on 24/7.

*albi1cnobi1* · 07-06-2011, 02:23 PM

It is if you DVR it... Lois is hot. Sorry did I type that. Supposed to be inside voice.

*snoranger* · 07-06-2011, 02:33 PM

I only TiVo the new episodes. I have all the old seasons on dvd. (including "partial terms of endearment" which wasnt aired in the US.)

*snoranger* · 07-06-2011, 02:47 PM

I'm looking for the stiffest torsion bars. It seems that the "1" bar is the stiffest (1.09" used in FX4 level IIs), followed by "B" (1.06"). Looks like I will be swapping out the torsion bars. Thats ok, I have to do some front end work anyway. I need to do ball joints, they're starting to make noise. This is going to be a lot of weight on the front end, I gotta make sure its up to the task.

07-03-2011, 04:33 AM	#1
snoranger Elite Explorer Jackson, NJ 94 limited on 35's Join Date: Feb 2007 Posts: 2,117 Vehicle Specs (Original Poster)	Engine swap "Cummin" soon The time has come for another engine swap in my '95 4 door 4x4. The previous swap (SOHC/EEC-IV) isnt having problems, but the gas mileage is poor (15 MPG average over the past year). Here's the patient (95 4 door 4x4): And its soon to be replaced heart ('01 SOHC): So, you may be saying to yourself, "oh boy, another 5.0l swap." The thought had crossed my mind. I have a 94 Cobra, that could use a bigger engine. Here's the 5.0 Cobra engine that could be used: But this is my daily driver and needs to get good mileage. I work 35 miles from home. Thats 70 miles a day, 5 days a week, 50 weeks a year (2 weeks vacation) 17,500 miles a year just to get to work. Since I'm running the SOHC on the 95 EEC-IV computer, the higher compression requires me to run 93 octane. Lets do some simple math: 20,000 miles 15 MPG $3.75 a gallon (checked the price today on my way home) Thats $5000 a year in fuel. What can i swap in that makes power, get good mileage, and will last a few years you ask? Thats right folks.... Its a Cummins 4bt! An 84K mile, 105 HP, 265 ft-lb 3.9l turbo diesel. She's a little rusty and the turbos got some play, but for $1200... not bad. It also came with a Neon SRT4 intercooler and an aftermarket header. She's clean inside! __________________ 94 limited: 4.0l, 5spd swap, 6" skyjacker lift, 35x14.5 thornturds, 4.56s. 5.0 swap started (94 cobra 5.0, zf 5spd, np205) 95 xlt: stockish (SOHC swap, 30,000miles and I blew up the 3rd 4r55e...now collecting parts for a Cummins swap.) Cummins 4BT swap thread Ranger bed trailer build

07-03-2011, 05:06 AM	#2
snoranger Elite Explorer Jackson, NJ 94 limited on 35's Join Date: Feb 2007 Posts: 2,117 Vehicle Specs (Original Poster)	Now, you may be saying that diesel fuel is more expensive, it will cost more to run. Most fuel estimates for this engine in a smaller truck or SUV seem to be in the 30 - 35 MPG range. Lets take that previous number of 20K miles a year. 20,000 miles 30 MPG $3.80 per gallon (checked today) That works out to $2533 a year in fuel costs. Quite a bit of savings. Now lets put all that stuff behind us and get down to the big question. Will a 750 lb, 4cyl engine fit in a 95 Explorer at stock height (or close to it) and still retain 4WD? Good question, let see. Looks like I will have to mod the oil pan, and make some more room for the starter. Nothing too bad. Height looks good...the hood will close. As it sits is 1/2" higher then the SOHC. So after the oil pan mods, I should be able to drop it down 2" or so. That will put the top of engine about 20 1/2" above the frame rails. I still have to get some exact measurements front to back. Best estimate is that I'll have about 3" of clearance between the elec fan and the front of the engine. I'm going to get some before and after weights, we have a scale at work, just have to wait till Tuesday. __________________ 94 limited: 4.0l, 5spd swap, 6" skyjacker lift, 35x14.5 thornturds, 4.56s. 5.0 swap started (94 cobra 5.0, zf 5spd, np205) 95 xlt: stockish (SOHC swap, 30,000miles and I blew up the 3rd 4r55e...now collecting parts for a Cummins swap.) Cummins 4BT swap thread Ranger bed trailer build Last edited by snoranger; 07-03-2011 at 05:53 AM.

07-03-2011, 08:00 AM	#3
2000StreetRod Elite Explorer Greenville, SC 2000 Sport SOHC 2WD Join Date: May 2009 Posts: 5,666 Vehicle Specs	what transmission? You are planning an interesting swap. What transmission are you considering? __________________ My Helpful Threads, Registry, 16.4/23 mpg, 3900 lbs, 5R55E, 3.73:1, 175 rwhp, Henson custom tune, CAI, Spectre air filter, Lightning 90mm MAF, 75mm throttle body, A/F ratio meter, synthetic oils, Accusump, 2 row radiator, 3+1 leaf springs, .75 inch drop, Edelbrock IAS lowering shocks, engine oil & ATF temp gauge & remote filters & coolers, remote crank

07-03-2011, 08:08 AM	#4
BrianDye Elite Explorer Michigan 04 CV LX Sport Join Date: Mar 2009 Posts: 5,606 Vehicle Specs	!!! __________________ '13 Dodge Charger RT

07-03-2011, 10:08 AM	#6
Tbars4 Offroad Moderator anaheim hills,california 95 ranger 4x4/ 91 X 4x4 Join Date: Mar 2007 Posts: 22,170 Vehicle Specs	..Subscribing... __________________ I have Rocks in my head. What's in yours? '95 ranger xl 4x4 2.3L std cab, 2 sticks Ranger RegistryThe Squirrel '91 4x4=To much to list, much more to add.. Project "X" and more Pics & Mod's List How to: Wheels,Tires, & Lifts... Buy Explorerforum.com Items here

07-03-2011, 07:32 PM	#7
NHarris Wannabe Elite Explorer Ogden, UT 1998 XLT V6 Join Date: May 2010 Posts: 3,477 Vehicle Specs	Subscribing to this. __________________ Nate H 1998 Ford Explorer XLT 4.SLOW Restoration Project - OEM Restoration with larger than stock tires. 2004 Jeep Grand Cherokee Laredo - 3.5" Lift, Quick Disconnects, Rear Locker, Mopar Off Road Package, Gray Moab Wheels, Differential Skid Plates, and much more!

07-03-2011, 08:41 PM	#8
Jarubell Wannabe Elite Explorer Was Winnipeg, Manitoba now Dartmouth, Nova Scotia, Canada RIP 92 XLT Join Date: Aug 2006 Posts: 200 Vehicle Specs	Subscribing to this too!

07-03-2011, 09:31 PM	#9
Ranger379 Wannabe Elite Explorer middle of nowhere, PA '99 XLT 4X4 4.0 OHV Auto Join Date: Dec 2005 Posts: 1,034 Vehicle Specs	subscribing also! __________________ 1999 Ford Explorer XLT 4x4 4.0 OHV Auto -Lifted! 3" BL and 2inch TT, Shackles and AAL's- 32x11.50's awaiting final pieces for the 5speed swap with 1354M 1995 Ford Explorer XLT 4.0 OHV 4x4 Auto - Stock 2000 Ford Expedition XLT - 5.4 4x4 RIP: 1996 Ford Explorer XL 4x4 4.0 OHV 5 Speed

07-03-2011, 11:45 PM	#10
snoranger Elite Explorer Jackson, NJ 94 limited on 35's Join Date: Feb 2007 Posts: 2,117 Vehicle Specs (Original Poster)	I ordered some parts. -AC/ alt mounting bracket....$45 used. (yes, I'm planning to run A/C) -Turbo rebuild kit.... $40 -Motor mounts... 13.44 (for both!) -trans mount... $13.87 I also dug out some other parts: -Sanden SD7 A/C compressor.... NIB $48.56 shipped (I bought 2 of these a while ago for an OBA setup I built.) -Flex-a-lite 1st/2nd gen Ranger fan...... $??? no clue. (I bought it new years ago, it didnt fit my 90 4.0l w/ heavy duty cooling. i'll put it too good use now.) __________________ 94 limited: 4.0l, 5spd swap, 6" skyjacker lift, 35x14.5 thornturds, 4.56s. 5.0 swap started (94 cobra 5.0, zf 5spd, np205) 95 xlt: stockish (SOHC swap, 30,000miles and I blew up the 3rd 4r55e...now collecting parts for a Cummins swap.) Cummins 4BT swap thread Ranger bed trailer build

07-04-2011, 12:48 AM	#11
Hitchhikingmike Wannabe Elite Explorer Dallas, Texas '02 XLS Join Date: Jan 2008 Posts: 1,524 Vehicle Specs	Subscribed! __________________ -Mike

07-04-2011, 09:55 AM	#12
ghosttrain2 Elite Explorer Winnemucca,NV 1994 XLT Join Date: Apr 2008 Posts: 339 Vehicle Specs	Subscribing __________________ Now residing in Northern Nevada ASE Master Mechanic since 1984 1994 XLT, 4.0 SOHC, 5R55E trans,dual tanks http://photobucket.com/davesexplorer My rebuild thread: http://www.explorerforum.com/forums/...d.php?t=283197

07-04-2011, 05:16 PM	#13
blueka Elite Explorer Saskatchewan, Canada 97 UK XL & 99 Sport V8 Join Date: Dec 2005 Posts: 4,614 Vehicle Specs	subscribing.. very interested in doing this in the future.... Si __________________ '97 Explorer XL 4.0 SOHC V6 "Betty" '99 Explorer Sport Limited 5.0 OHV V8 "Pickle" My "Betty" Registry My "Pickle" Registry

07-04-2011, 05:24 PM	#14
The Electrician Lifted & Loaded Makkah 2008 XLT 4WD V6 Join Date: Feb 2011 Posts: 495 Vehicle Specs	subscribing, inserted to see how would you end it __________________ - Allaa' - Basic Off-Road Techniques 2008 Explorer XLT 4WD V6 - Lifted & Loaded 2000 Crown Victoria P71: 4.6 PI Engine Swap, MZT, 70mm TB, P&P Plenum, Steeda UDP, J-Mod, B&M Trans Deep-Pan, External Trans Oil filter, BOC Tuning

07-06-2011, 01:07 PM	#15
snoranger Elite Explorer Jackson, NJ 94 limited on 35's Join Date: Feb 2007 Posts: 2,117 Vehicle Specs (Original Poster)	Little update: Pyrometer ordered. I'll have it thursday. Talked to the warehouse today. I'm taking the truck over to get weighed later today. If anyone in the area has a used steering rack (good or bad) they can let me use to mock this up, let me know. __________________ 94 limited: 4.0l, 5spd swap, 6" skyjacker lift, 35x14.5 thornturds, 4.56s. 5.0 swap started (94 cobra 5.0, zf 5spd, np205) 95 xlt: stockish (SOHC swap, 30,000miles and I blew up the 3rd 4r55e...now collecting parts for a Cummins swap.) Cummins 4BT swap thread Ranger bed trailer build

07-06-2011, 01:43 PM	#16
albi1cnobi1 Elite Mountaineer South Jersey 99 Mountaineer V6 4x4 Join Date: Dec 2007 Posts: 1,264 Vehicle Specs	Holy crap, man! I just found this thread, you are an industrious little bugger aren't you. I'll check my shed for the steering rack. I used to have one but I have a feeling it may have been scrapped in a previous shed clean out. I'll let you know. __________________ Al 99 Mountaineer 4.0 SOHC. TT/Warrior Shackles, 2" BL, 32x11.5/15 BFG A/T's, Rancho 5000's, Supplemental HHO Generator(out for cell redesign), Electric Fan Conversion, AVM Manual Lockout Hubs, Dual Battery System, Gibson cat back exhaust. EATC Mod. BW1354 swap, finally done! My 4405 To 1354 Swap Thread Support your own economy, Buy American, all of our jobs depend on it.

07-06-2011, 02:23 PM	#18
albi1cnobi1 Elite Mountaineer South Jersey 99 Mountaineer V6 4x4 Join Date: Dec 2007 Posts: 1,264 Vehicle Specs	It is if you DVR it... Lois is hot. Sorry did I type that. Supposed to be inside voice. __________________ Al 99 Mountaineer 4.0 SOHC. TT/Warrior Shackles, 2" BL, 32x11.5/15 BFG A/T's, Rancho 5000's, Supplemental HHO Generator(out for cell redesign), Electric Fan Conversion, AVM Manual Lockout Hubs, Dual Battery System, Gibson cat back exhaust. EATC Mod. BW1354 swap, finally done! My 4405 To 1354 Swap Thread Support your own economy, Buy American, all of our jobs depend on it.

07-06-2011, 02:33 PM	#19
snoranger Elite Explorer Jackson, NJ 94 limited on 35's Join Date: Feb 2007 Posts: 2,117 Vehicle Specs (Original Poster)	I only TiVo the new episodes. I have all the old seasons on dvd. (including "partial terms of endearment" which wasnt aired in the US.) __________________ 94 limited: 4.0l, 5spd swap, 6" skyjacker lift, 35x14.5 thornturds, 4.56s. 5.0 swap started (94 cobra 5.0, zf 5spd, np205) 95 xlt: stockish (SOHC swap, 30,000miles and I blew up the 3rd 4r55e...now collecting parts for a Cummins swap.) Cummins 4BT swap thread Ranger bed trailer build

07-06-2011, 02:47 PM	#20
snoranger Elite Explorer Jackson, NJ 94 limited on 35's Join Date: Feb 2007 Posts: 2,117 Vehicle Specs (Original Poster)	I'm looking for the stiffest torsion bars. It seems that the "1" bar is the stiffest (1.09" used in FX4 level IIs), followed by "B" (1.06"). Looks like I will be swapping out the torsion bars. Thats ok, I have to do some front end work anyway. I need to do ball joints, they're starting to make noise. This is going to be a lot of weight on the front end, I gotta make sure its up to the task. __________________ 94 limited: 4.0l, 5spd swap, 6" skyjacker lift, 35x14.5 thornturds, 4.56s. 5.0 swap started (94 cobra 5.0, zf 5spd, np205) 95 xlt: stockish (SOHC swap, 30,000miles and I blew up the 3rd 4r55e...now collecting parts for a Cummins swap.) Cummins 4BT swap thread Ranger bed trailer build