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1992 Explorer 5.0 swap thread

Discussion in 'Offroad Drivelines' started by Kris Guilbeaux, June 5, 2012.

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    1. Kris Guilbeaux

      Kris Guilbeaux Elite Demon Secretary Staff Member Moderator Elite Explorer

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      Recently started the 5.0 swap on my 1992 Ford Explorer Jurassic Edition, after the rebuilt manual transmission failed after a bad syncro locked it in fourth gear.

      This swap will retain the existing firewall and dash. The engine bay harness will be removed and will use a custom built 97/92 Engine bay harness. All second gen locations for the air box, battery, overflow, and cruise control will be used. AC and emissions will be retained on this Explorer. Also the Factory column shifter will be used.

      The 5.0 is coming from a 97 Explorer and the trans will be a 4r70w from a 97 AWD explorer. The only thing I will use different is a 92 Ford bronco 1356 transfer case elec shift.


      The 97 5.0 I picked up for a song and dance.
      [​IMG]

      Home on the Engine Stand.
      [​IMG]

      Removed the drive train
      [​IMG]

      [​IMG]

      [​IMG]

      [​IMG]


      Then you have to make it clean for that new motor.

      [​IMG]

      we then moved the battery tray and airbox to the new spots for test fit.

      [​IMG]

      [​IMG]

      At this point we are at a slight stand still till Russell starts the wiring harness and he has mapped the harness out.

      I also need to purchase my motor mounts so I can test fit the motor in the engine bay.
       
      Last edited: July 21, 2014
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    3. Randall

      Randall Demon4x4 Member

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      Is that an early 97 motor, i.e. pre PATS?
       
    4. Kris Guilbeaux

      Kris Guilbeaux Elite Demon Secretary Staff Member Moderator Elite Explorer

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      Why Yes Randall, 97 is pre pats..
       
    5. Randall

      Randall Demon4x4 Member

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      Well, I had read that only the early 97's were pre PATS, and not all 97's, so I just wanted to make sure. ;)
       
    6. Kris Guilbeaux

      Kris Guilbeaux Elite Demon Secretary Staff Member Moderator Elite Explorer

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      nope all 97 is pats free
       
    7. NICE59FORDF100

      NICE59FORDF100 Staff Member Moderator Elite Explorer

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      What Kris doesnt know is I am secretly adding TWO pats modules, MUWAHAHA
       
    8. Kris Guilbeaux

      Kris Guilbeaux Elite Demon Secretary Staff Member Moderator Elite Explorer

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      Motor Mounts will be here Monday so I can start test fits.
       
    9. GuardianSport

      GuardianSport Active Member

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      Subscribing.

      4R70W trans, or M5OD?
       
    10. Kris Guilbeaux

      Kris Guilbeaux Elite Demon Secretary Staff Member Moderator Elite Explorer

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      4r70w
       
    11. NICE59FORDF100

      NICE59FORDF100 Staff Member Moderator Elite Explorer

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      :d
       
    12. NICE59FORDF100

      NICE59FORDF100 Staff Member Moderator Elite Explorer

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      So today we did the following on jpx:

      1)Removed the upper intake
      2)Repaired the temp sensor circuit on the motor (the two wires were missing for some reason)
      3)I added a low oil level circuit to the engine harness so the first gen switch/"Check Oil" light will be functional
      4)Finished anchoring the second gen coolant/washer reservoir to the apron
      5)Bent back the firewall seam and reattached the exhaust heat sheild.
      6)Added a second gen A/C Dryer to the the first gen air box assembly (so second gen a/c lines will attach to it)
      7)Swapped back in an Automatic Transmission brake pedal (JPX was manual)
      8)I dropped the gas tank
      9)I built a hybrid Gen 1/Gen 2 frame electrical harness to incorporate the fuel tank pressure transducer and EVAP canister purge solenoid. This was all done while still utilizing the stock 12 pin connector (1992 C141) as a stock second gen does. I also swapped out the stock 4 pin fuel sender assembly connector (1992 C331) with the 97' 8 pin connector for stock retention of the fuel sender assembly with pressure transducer.

      More progress and pictures tomorrow, but our arbitrary deadline I recklessly set forth is a first fire by end of july. Motor mounts will arrive monday, and test fitting should occur later this week. So all in all, today was a great day! Oh, and I am designing and engineering the A/C system in with the motor swap so that when we fire up the motor, the A/C system will already be in place and ready to be charged with coolant. So stick with us, this will be a real interesting 5.0 swap ;)
       
    13. NICE59FORDF100

      NICE59FORDF100 Staff Member Moderator Elite Explorer

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      following the progress of saturday, sunday we finished up the fuel tank and some other little things.

      1)Modified the first gen gas tank to accept the pressure transducer in the tank, it was mounted on top next to the vent tube.
      [​IMG]
      2)kris installed the second gen charcaol cansiter which is mounted above the spare tire.
      3)ran all the related EVAP lines along the frame rail and to the fuel tank.
      4)Installed hybrid frame harness
      5)reinstalled the fuel tank and skid plate (I hate fuel tanks just for this reason lol)

      So sunday was productive in the fact that all the underside/rear vehicle modifications were done and ready to go. Next step is to install the motor mounts and test fit the motor (today)
       
    14. Kris Guilbeaux

      Kris Guilbeaux Elite Demon Secretary Staff Member Moderator Elite Explorer

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      Added some clearance to the firewall

      [​IMG]

      Russell adding the Transducer

      [​IMG]

      Added the second gen evap system

      [​IMG]

      [​IMG]

      New Frame harness

      [​IMG]

      [​IMG]

      [​IMG]

      [​IMG]

      5.0 in but oil pan is keeping it from being dropping down all the way.

      [​IMG]

      [​IMG]

      [​IMG]
       
      Last edited: July 21, 2014
    15. dking

      dking Elite Explorer

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    16. SuRrEaLNJ

      SuRrEaLNJ hail to the king, baby! Elite Explorer

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      following this
       
    17. IAmTodd

      IAmTodd 4x Explorer Veteran

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      Looks great. I should have done this to mine while I had everything out.
       
    18. NICE59FORDF100

      NICE59FORDF100 Staff Member Moderator Elite Explorer

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      yep, the 5.0 fits real nice in there. Granted once we figured out the james duff mounts it finally sat in there good. but it still looks like we are going to need a duel sump oil pan to clear the drop bracket and to allow clearance with the passenger side traction beam. so stay tuned!
       
    19. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      I love it. Have fun with it.

      The fuel tank mod interests me. I'm soon going to attempt to reuse my old 93 tank and attach the metal top section from a spare 98 Sport tank I have. I want the later sensors also, plus the later pickup assembly.

      FYI, I have a brand new 91-94 assembly from Ford that I'm not going to use now. I was afraid to mess with the grafting of the metal to the plastic tank, until I saw how the sensors are screw in devices. They have seals which work by having the sensor screw in and down more in depth than the thickness of the plastic. I think it will be easier to cut out two sections of the steel tank, and bolt/epoxy those to the plastic tank. I'll find out, I bought a fuel sealant product for about $20.
       
    20. BradR

      BradR Active Member

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      Ya'know, having you both as friends on FB (Kris,Russ) this whole thread looks so vaguely familiar.... hmmm....
       
    21. adamsbro2

      adamsbro2 Bryan Elite Explorer

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      Sweet!!! Subscribed!!! :popcorn:
       
    22. rookieshooter

      rookieshooter Moderator Emeritus

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      Gotta love an engine that is about as squared as a motor can get with it's 4"x3" (302 CI) (4.9 L) bore/stroke ratio and then at firing at every 90 deg. Now if I could only see the engine in those pics. I was able to make out a hint of a valve cover.
      Like the way your thinking this out.
       
    23. ahodges

      ahodges Elite Explorer

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      Looks great. Some insight to your oil pan issue: 96-98 used the cast aluminum oil pans where the 99-01's used a stamped steel pan. I ran into the issue of oil pan clearance when I dropped the 5.0 into my 96 with the disconnect axle style. My solution was to just put a 97 front axle in. In your case I don't see anyway around getting a later model oil pan and modifying it. It's far easier to modify a steel pan than a cast aluminum one.
       
    24. Randall

      Randall Demon4x4 Member

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      Is the only interferance with the current pan the drop brackets/current I-Beam? So those with a different axle set up (i.e. solid axle) would have no worries there?
       
    25. Kris Guilbeaux

      Kris Guilbeaux Elite Demon Secretary Staff Member Moderator Elite Explorer

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      Yes Randall you are right. Any one with a SAS on there explorer or was 2wd would be ok to run this pan.

      I did purchase a Mudstain pan on Ebay last night. hoping with the new pan all will provide the clearance and if not they are stamped steal which is easier to modify.

      Also the EGR port covers on the GT40 heads from the 97 Motor hit the fire wall on the driver side. I am thinking of making a thiner cover and moving the motor back another 3/8" or so.
       
    26. Bruces expo

      Bruces expo Elite Explorer

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      Sweet Build , JPX Is Awesome ! I Remember When It First Was Painted And Now The 5.0 Swap NICE ! Subscribing !
       

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