410Fortune - 96 5.0L XLT refurbish (making 1 great Ex from 2)

[EMG7895]

I'm going to be doing the same thing, but with a 93 and 94 this summer. What are the plans for whats not used? Part out and scrap?

 

[410Fortune]

I plan to keep my "spare" drivetrain because I have the same 5.0L and transmission in my BII and my 96 Explorer now.
They will go into storage. The 5.0L has 151K miles on it and the trans was slipping when I pulled it.
This explorer is being built to DD and tow the boat.

It now will have 81K original 96 miles on it, engine, trans, rear axle, drivelines, transfer case, exhaust, CV's, shocks and rear springs..
The only thing thaty stayed is the wiring. (from my rolled truck)
the BII had 53K on it from a 97.5 donor when I did the conversion last year.
This drivetrain may become a 331 stroker to power the BII

the other parts I have, doors, hoods, Gen II explorer parts I will likely strip down and keep. I collected body parts for this blue truck and on Craigslist found some great deals on more parts then I need currently, but they are Gen II parts, 95+


My green rolled truck will get stripped to the cab and then crushed. I have some friends who already have dibs on parts, but they will not fit your 93-94 really. The 93-94 trucks are basically the same, with the 94 having EGR. (93 CA trucks have EGR)

I purchased the cam and timing set from a local speed shop.
They helped me get the right parts when I was doing the 5.0L conversion so I figured I would throw them a bone.
They could not locate a waterpump for my engine.
The aftermarket lists the 96-01 Explorer engine in the same catagory as the late model stang 5.0L. they ordered me a water pump ,it was the wrong one.
The Explorer GT-40 uses a different timing cover and accessory brackets for the front dress.
The OEM waterpump (I have two, both have fans mounted to them that were damaged, I do not trust) is a high volume unit from the factory, so it will suffice.
I will get one from Ford or online.

the 5.0 fans are also expensive, looking at the junkyard.
I have a line on airbags, brain and sensors used with a tan dash so it will take some painting (blue interior)
I got the hitch on EF for el cheapo, but the rear bumper on this truck is actually bolted to the body, after the body lift install, so it will take some work.

 

[Glacier991]

I know JUST the 4R70W you need !!!

 

[SkanlaxJMO]

410 just curious about parts from the 96....do you have one of those rubbery things that goes in the cupholder?.......it is a pita without one.........what about doing an electric fan somthing like aldive did?

 

[BigDakota]

Damn 410..I have missed alot of this thread...you are moving right along....I bet this niceweather is getting you anxious to get this project done
That was a smoking deal deal..900 bucks for the 5.0 X.....keep a look out for another one of those deals for me ..I am planning to put a V8 in my Sport.........PROJECT SPORT..

 

[410Fortune]

Your sport will be easy to put a 5.0L into, its already ready already

I will be running a mechanical fan on my 5.0L because this truck is used for towing and long road trips with the AC on, I dont trust electric fans for this application.

I am super anxious to get this truck running, it will also allow me to put my focus back on the BII for "stage III", the BII has badly needed some attention to the body work for years now...., I want my full garage back! I have explorer parts everywhere!

We're getting close now baby, I talked to Robert of TM headers last night for a bit, the TM headers for this truck are on their way!!! And yes I paid for them hahaha

Hell yes!

Funny the state of CO sent me a emissions renewal for my rolled truck, hahaha if they only knew....

 

[r37ribution]

Dude, hearing about your 5.0 install makes me wish the 5.0 deal i was looking at for $800 didn't fall through.

Sounds great man, good luck.

 

[410Fortune]

Keep looking!!
They are out there, I see them all the time.

This truck was a 5.0L to begin with, but it had 151K miles on it, and the truck I rolled has 83K on it so I swapped drivetrains....both 96 5.0L AWD drivetrains.

 

[410Fortune]

Does it feel like Christmas to you guys?
hahaha I have had parts flying in for this project for the last couple of weeks now.
Today I get the TM headers, OH BABY, yup like Christmas.

I am working on this Explorer this weekend, I plan to have it running on Monday with the rad support tacked in place.

Waterpump is coming, I found a Bosch brand new online for $61 free shipping.
This afternoon I see a man about some airbags from a 98 and some other misc parts
Only part I do not have is a 5.0L fan, both of mine are FUBAR'ed.

Next week I will swap the 8.8, leafs, rear bumper, and rancho's from the rolled truck...install my new hitch, the body lift comes off, new windshield and custom exhaust go on, then looking for rims and tires, oh and CHARGE THE AC!!!

 

[section525]

Torrie has windshields for like $160 plus $7 shipping. I may go that route if I can get someone to come out and install it. Unless you can do it and will be in Chico sometime.

 

[410Fortune]

In CO I have found BII windshileds for $90 installed and Explorer glass for like $135. Colorado residents use up alot of glass!

Plan is to also have my friends Brian and Cindy buy new glass for their cars at the same time. Then you just have the van come out and do all 4 cars at the same time and cut a great deal.

I will remove the glass from the BII myself the day before because I need to take the surround down to bare metal this time...a bit of surface rust under there.....

 

[r37ribution]

Let me know if you need air bags, I pulled 2 good blue ones from a junker. If you need the module, I have that too.

 

[410Fortune]

WHERE HAVE YOU BEEN????


PM sent

 

[410Fortune]

OH baby BLING BLING

Torque Monster Headers are installed.

Took me all of 1 hour working slowly to make sure I got a good fit.
It is really easy with no radiator support and an almost bare engine block, no fenders, etc.

The headers fit perfect, no issues, and all the bolts were easily accessible with a 1/4 drive 10mm socket or 10mm wrench.

First the kit as it came from Robert:

These are the 96 (non p head, no EGR bung) "smooth tube" headers.
Quality is amazing, as usual.

First I had to install the engine mount nuts on the mount studs:

Then 15 minutes later:

The Explorer version is much easier to fit on the engine then the conversion style I have on my BII. NO issues with threading the bolts or clearancing the port tubes.

Each bolt got blue loc tite (included) and threaded finger tight, then the manifold and gasket are lined up and slowly torqued down from the middle working out

Clearance:

Overhead:

On to the drivers side, again 15 more minutes:

You can see the 3" body lift on this truck causes some issues with the header/steering shaft clearance. The adapter that is used to extend the stock shaft for the body lift will not fit, I wouldn't use it anyways. Since it may be a while before I get the body lift off (need tires, etc) I will likely weld up an quick fix on a donor shaft (rolled truck) and call it good.


Gorgeous! Thanks again Robert!!
Tomorrow the rest of the exhaust goes in place, and the cam install begins...should be running next week.

Also BLUE airgbags coming next week! Gotta love EF...

 

[section525]

The new 10mm header bolts are super bling and make for a much easier install. Way to go Robert!

Oh yeah, you're doing good too, Jamie.

 

[r37ribution]

damn those look sexxxay.

He should make some 4.0L OHV headers...or does he already?

 

[410Fortune]

No TM only makes the headers for the limited 5.0L Explorer and conversion market.
Most companies who made 4.0L OHV performance parts have moved on, I assume its not a very profitable market for them vs production costs. Borla and JBA still offer OHV headers.

 

[410Fortune]

Okay update...

I am ready to install my cam, well almost.
I ordered the Ford Motorsports 1.6 roller rockers, springs and retainers. Will be here tomorrow

Harbor Freight had a spring compressor for $7, install should be possible in the truck without removing the heads (Thanks Section!)

3 way puller installed on crankshaft pulley:

After (front main seal):

timing cover removed (timing chain and gears visable):

Valve covers removed (stock 1.6 stamped rockers and valvetrain):

I may have to remove the headers to get the spring compressor to work but thats no big deal (hopefully not), it's better then pulling the engine again or the heads

I cannot wait, should be able to button up this truck this weekend and be ready for the radiator support spot welding, then final plumbing and front clip install....

Sweeett!!

estimates with these mods are approx 300 HP+ at the crank

 

[section525]

Good luck! Don't lose any valves!

 

[410Fortune]

I am having help come over, a friend who has done heads before, I will keep those valves from dropping!! Did you really have to find TDC 16 times? Also what type of spring compressor did you use?

I am psyched that all my performance parts are Ford Motorsports too Might have to make some white FMS gages for the Gen II now