I see this one has been quiet for a while, but I just came accross it and would like to add some info. I think that most, if not all the suggestions as stated are very helpful and worth while.
One thing we've done here at Tech Performance & Engineering is to include ideas to build on after installing Torque Monster Headers, which include most everything stated already. It's called "Add-Ons After Headers"
After installing Torque Monster Headers, these are Add-Ons that may appeal to your more Horsepower/Torque requirements.
Add-Ons: Stage 1
* K&N air filter stock element replacement, or
* K&N Cone element to replace stock Air Box.
* JBA Spark Plug (Ignition) Wires, PN 06239 (jbaracing.com), or your preferred brand.
* Ford Motorcraft Spark Plugs or your preferred brand.
* 2 - MSD, Ford Coil Packs, 4-Tower, PN 8241, or your preferred brand (Accel, etc.).
* Install Cat Back Exhaust System. However, make sure to install a system with back-pressure to include a resonator that will give you the required back-pressure. The stock computer settings (o2 sensors) work better with back-pressure.
Consider, Dynamax, Flo-Pro, or Gibson for systems that have the required backpressure.
These Stage 1 changes, along with Torque Monster Headers, should net you about 30-35 HP and about the same in TQ and should not require a chip change, yet. However, if you install a super free flowing Cat Back Exhaust System and a new MAC air intake at this point, you will need to chip the vehicle.
Add-Ons: Stage 2
* 8 - Bosch Spark plugs, Platinum +4, PN 4458, or your preferred spark plug manufacturer.
* 1 Set of 8 - Nology Spark Plug (Ignition) Wires, PN 014208001, or your preferred spark plug wire manufacturer.
* 2 - MSD, Ford Coil Pack, 4-Tower, PN 8241
* 1 - MSD Digital DIS-4 Plus, PN 62152
2 - Tach Adapters, PN 8912, must be installed with MSD Digital DIS-4 Plus.
* MAC Air Intake System or preferred manufacturer, complete replacement for stock Intake unit.
* 16 - Ford Racing, Roller Rocker Arms, PN M-6564-B351
* 1 - Ford Racing, EFI Heat Spacer, 1" thick, Fits between upper and lower manifolds to help dissipate
heat and significantly increase performance. PN M-9486-A53 This item can be added in Stage 1
without worry of having to chip the engine. You can add another 5-10 hp to Stage 1.
* Exhaust system from the CATs to the rear bumper. Your choice, many ways to do it. If you have more
than 100,000 miles on the vehicle, replace the catalytic converters. Order from Ford.
* Reprogram your computer/engine management system. Contact "http://www.bamachips.com" or your
preferred retailer for your needs. This is a “Must Do” at this point!
These are Stage 2 Changes, along with Torque Monster Headers, should net you about 55-60 HP and about the same in torque.
Add-Ons: Stage 3
* Powerdyne, Eaton supercharger or preferred supercharger manufacturer. Purchase the Eaton from Explorer Express
(explorerexpress.com). They also have loads of other things which may catch your eye.
* Stroker engine: 331, 342 or 347 cubic inch are the most popular. Purchase from Coast High Performance (coasthigh.com), Ford Racing or your preferred manufacturer.
* Rebuild Transmission with shift kit, etc. Baumann makes a great shift kit for the Explorer transmission. This can also be done in Stage 1 or 2. The reason it’s in Stage 3 is because it’s a big ticket item unless you do it yourself.
For more info on our Headers, please refer to the Purchasing guide on Explorer Forum:
http://www.explorerforum.com/forums/showthread.php?t=147452
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