2001 EB 5.0 AWD daily driver project build

[MetricMuscle]

This is my first post as the proud new owner of my first Explorer. I have perused this forum quite a bit and read up on most threads pertaining to the mods I'm interested in.

My goals: Mostly street driven SUV that will work well in the snow, good balance between plushness and control in the suspension department, improve power and fuel efficiency, try to resist over-modding as I have done with every other thing I own.

If I have understood the various shock upgrade threads, Monroe 58617 Load Adjust Shocks in the rear and Rancho RS55229 or RS55374 in front. This will correct the sag in the rear and improve control but still with a great ride.

Exhaust header selection is very limited due to the clearance needed for the "P" head spark plug angle and tight confines of the engine bay. Looks like most of the headers attempted to connect to the OE downtubes. What about a full length header that would require a complete exhaust change? Are there any that will work with these heads and fit in this chassis? Once underneath and around the transfer case there looks to be ample room for the rest of a proper exhaust system.

The 4406 mod looks like a good way to improve a few things. Better fuel economy, better driving feel when in 2H, real 4WD when needed.

 

[Mbrooks420]

The only real header option is Torque Monsters. There were a few others, but they were garbage build quality.

To properly fix the rear and sag you will need to replace the leaves. The coil spring shocks might add a little lift, but are a band aid fix, and likely won’t bring he truck back to
level.

 

[MetricMuscle]

The only real header option is Torque Monsters. There were a few others, but they were garbage build quality.

To properly fix the rear and sag you will need to replace the leaves. The coil spring shocks might add a little lift, but are a band aid fix, and likely won’t bring he truck back to
level.

Thanks for the info.

Is the issue with other header options just clearing the spark plugs or being able to connect to the OE down tubes or both? The motor mounts, upper control arm mount and engine to frame closeness look to be the other culprits.

I have found a couple of threads discussing options for replacement leaf springs, various possible donor candidates or new aftermarket parts. None really settled on which way to go, what would you recommend or is there a thread I missed on the best replacement option?

Thanks again for you help!

 

[Mbrooks420]

The header issue is clearing the steering shaft and fitting inside the frame. There’s no off the shelf header that will fit, unfortunately.

 

[410Fortune]

hmmmmm

There are headers that will fit the engine and clear the steering shaft, but not connect to the factory downpipes
GT40 headers will work on GT40p heads...just requires different spark plug boots
Some options require a notch in the passenger side frame rail
Anything other then the TM's will require custom downpipes

FMS manifolds/headers are still around I see from time to time
The old Mustang Tri Y manifolds have been known to work and flow up to 350+ hp
There are several aftermarket shorty headers built for 5.0 conversions, some of these can be made to fit the Gen II also
Torque Monsters are the best option but $$$$$, I do see they are for sale again .......

 

[Mbrooks420]

How come no one seems to use other headers with custom pipes between them and the factory down pipes?

 

[Blown]

I found some old air shocks for the rear, when they go I will bag the rear. That's my preference for a nice adjustable ride. Adding leaves is going to stiffen things up and drop it the thickness of the leafs giving a net lift only based on how arched they are. I added air shocks, removed the overload leaf, and added 2" shackles. It rides nice and I can pump it up when loaded or when in the dirt.

 

[Mbrooks420]

I liked the bags in the rear of mine.

 

[MetricMuscle]

hmmmmm

There are headers that will fit the engine and clear the steering shaft, but not connect to the factory downpipes
GT40 headers will work on GT40p heads...just requires different spark plug boots
Some options require a notch in the passenger side frame rail
Anything other then the TM's will require custom downpipes

FMS manifolds/headers are still around I see from time to time
The old Mustang Tri Y manifolds have been known to work and flow up to 350+ hp
There are several aftermarket shorty headers built for 5.0 conversions, some of these can be made to fit the Gen II also
Torque Monsters are the best option but $$$$$, I do see they are for sale again .......

So this style of shorty header will fit in the engine bay?

Looks like the driver's side dumps straight down in front of the differential and the passenger side angles back to clear the starter?

 

[410Fortune]

I'm not sure what headers those are? Conversion something they appear
The problem is this is an expensive path to find out of they do or do not fit, even with custom work
I know the FMS and TMH will work (obvious)
Heres other options, the path we are going down requires custom fab to the headers themselves or your truck:
I have seen the early 289 Tri Y fit a modified 4x4 explorer
Headman shorty headers 88400 or similar will work with pass side frame notch
F150 log style manifolds have been fitted also and look like they might work
Block huggers is what you need, custom downpipes will be required.........

 

[MetricMuscle]

I'm not sure what headers those are? Conversion something they appear
The problem is this is an expensive path to find out of they do or do not fit, even with custom work
I know the FMS and TMH will work (obvious)
Heres other options, the path we are going down requires custom fab to the headers themselves or your truck:
I have seen the early 289 Tri Y fit a modified 4x4 explorer
Headman shorty headers 88400 or similar will work with pass side frame notch
F150 log style manifolds have been fitted also and look like they might work
Block huggers is what you need, custom downpipes will be required.........

Those headers are listed on eBay as Stainless Steel Mustang headers, 79-93. They would just be a starting point for custom headers. I'd prefer to have longer tube headers than the TMH and made out of SS. I have an exhaust design program, PipeMax, which specifies a much different design than anything I've seen discussed here. With peak power being made at 4,200rpm, header primary length should be around 50" long. Collector length could also be that long or half that length at around 27". According to PipeMax, Collector length has the greatest effect on power, 2nd is primary length, then collector diameter and lastly primary diameter. 1.5" diameter primaries are on the large side of what is recommended to start with.

The Tri-Y headers for 289/302 on eBay have different length merge points and get pretty large in diameter pretty quick. The motor mount and upper control arm look to be in the way of most traditionally designed headers.

So many modern engines use such strangely designed exhaust manifolds like the Explorer 5.0 does. Short little "T" connections etc. Briggs and Stratton doesn't even do this!

 

[MetricMuscle]

The header issue is clearing the steering shaft and fitting inside the frame. There’s no off the shelf header that will fit, unfortunately.

Upon further review, interference between cylinder #7 and the steering shaft is definitely the biggest obstacle I see. Would only need to be moved up just a little bit.

Looks like it would be lots easier to run them through the back of the fender well, over and along the outside of the frame rails. I'd feel silly even suggesting such an idea if the OE arrangement wasn't so wonky to begin with.

 

[410Fortune]

outside the frame is a good idea, many off road conversions end up this way, maybe not great for a stock truck not much room there but it is an option
You could always reverse them and mount a turbo somewhere! LOL
You can buy a header kit and build some?
So many options all of them $$$$$

 

[MetricMuscle]

outside the frame is a good idea, many off road conversions end up this way, maybe not great for a stock truck not much room there but it is an option
You could always reverse them and mount a turbo somewhere! LOL
You can buy a header kit and build some?
So many options all of them $$$$$

Well, if I started with something like this.........