Build the 4.0Lor swap to a V8

[Tim72]

Hello everyone. This may be discussed elsewhere and I missed seeing it, I apologize in advance. I have a 2001 Explorer Sport Trac, 2 wheel drive, basic model. It finally went down after 270,000 miles. My son has it in his head to do a "project build" on this Explorer. I been thinking of either rebuilding the 4.0, finding a 3.5L twin turbo, or trying to cram a small block V8 under the hood. I have been reading that the 4.0L can be built to equal a stock 302 but I'm not sure I want to deal with the 4 timing chains it may still need. Does anyone know if I could get rid of most of the timing chains and it'll still perform or will I still need all 4? Which would be better to throw under the hood like I mentioned before? Too many questions rattling around in my head before I attempt to get started. Any advice is welcomed. Thanks in advance.

 

[vroomzoomboom]

IMO converting to a 5L is the only way. it may be a bit more work upfront, but the reliability you will have with it and the trans afterward more then makes up for it. there have been a few that have done a 5L swap in a sport trac here, and guys that have also done a 5L swap in explorers as well.

 

[C420sailor]

You can eliminate one chain on the SOHC—for the balance shaft. That said, it doesn’t really gain you anything, and your 2WD engine likely doesn’t have one to begin with.

The trouble is related to the chains that feed the camshafts, and those are 100% necessary.

Don’t do an Ecoboost. Those engines are problems.

Either build up a fairly stock SOHC, or stuff a 5.0 in there.

 

[Josh P]

You need a 5.0.

 

[410Fortune]

5.0 fits like factory
2001 it is a 95% bolt in swap
Rwd makes it easier
The bonus is the 3/4 ton transmission
5.0 sport trax is the best of the best
I daily drive one
And we have two other 5.0 traxs here on the r property, the 302 is right at home in a sport trax

To rebuild a 4.0 is $$$$ and then what to do about your transmission? Usually when a v6 is rebuilt (big $$$) the transmission goes south soon after
Smart money is to put all that cash into something that will reward you like the pushrod 302 and its 3/4 ton transmission

302 sport trac will go another 270k

 

[Tim72]

IMO converting to a 5L is the only way. it may be a bit more work upfront, but the reliability you will have with it and the trans afterward more then makes up for it. there have been a few that have done a 5L swap in a sport trac here, and guys that have also done a 5L swap in explorers as well.

First off, thanks for the helpful insight. Second, with that bit of info, I may just go that route and to be honest, my son would learn a bit more having the chance to actually work on a "real" engine. I'm not dissing the 4L, it's been a great engine at over 250k in miles but I'm ready to go back old school.

 

[Tim72]

5.0 fits like factory
2001 it is a 95% bolt in swap
Rwd makes it easier
The bonus is the 3/4 ton transmission
5.0 sport trax is the best of the best
I daily drive one
And we have two other 5.0 traxs here on the r property, the 302 is right at home in a sport trax

To rebuild a 4.0 is $$$$ and then what to do about your transmission? Usually when a v6 is rebuilt (big $$$) the transmission goes south soon after
Smart money is to put all that cash into something that will reward you like the pushrod 302 and its 3/4 ton transmission

302 sport trac will go another 270k

Well, you got me sold. I think I'm going to go that route. What are your thoughts about either adding a turbo or supercharger to it? Like I said before, I want this thing to be deceptive and run like hell.

 

[vroomzoomboom]

Well, you got me sold. I think I'm going to go that route. What are your thoughts about either adding a turbo or supercharger to it? Like I said before, I want this thing to be deceptive and run like hell.

you will really need to know your stuff if you do that. there are no kits made for these trucks. you would have to scratch build your own. not that this is impossible, im on my 3rd set up for a supercharger as well as a member on here that lives 20 mins from me did his own turbo kit then sold the truck to me, which i pulled everything off it and resold it.

 

[Josh P]

Well, you got me sold. I think I'm going to go that route. What are your thoughts about either adding a turbo or supercharger to it? Like I said before, I want this thing to be deceptive and run like hell.

Boost is addictive. If you go that route invest in an aftermarket block. Some would say it's not necessary but it should be looked at like an insurance policy.

 

[410Fortune]

Couple of ways to approach this
Convert the truck over now and come back later with the power adders
Or go full on big power from day one
Budget and time

A ford small
Block can make some serious power even without the boost …
I would ask my customer
What is your budget?
What is the intended use of the vehicle?

A 302, 306, 331 or 347 crate engine can be a lot of fun in a sport trac and not terrible to fit

 

[vroomzoomboom]

i would go with 410fortune on this. get the motor in, work out any bugs, enjoy it for a while then go full plaid on it. speed is money, how fast do you want to go. also a aftermarket block is nice, but your not building a race truck. ive survived with production ford blocks for years. they are good for around 600 horse with a tuner that knows how to tune.

 

[Tim72]

you will really need to know your stuff if you do that. there are no kits made for these trucks. you would have to scratch build your own. not that this is impossible, im on my 3rd set up for a supercharger as well as a member on here that lives 20 mins from me did his own turbo kit then sold the truck to me, which i pulled everything off it and resold it.

I'm honestly leaning towards putting a supercharger on it rather than a turbo. Really don't feel like doing the plumbing. So with that I think I've got the route I'm going when I do this. Oh, one more question. What about full time awd? What are your thoughts about adding the necessary equipment into this?

 

[94Eddie]

I'm honestly leaning towards putting a supercharger on it rather than a turbo. Really don't feel like doing the plumbing. So with that I think I've got the route I'm going when I do this. Oh, one more question. What about full time awd? What are your thoughts about adding the necessary equipment into this?

A Roots or twin screw supercharger will give you instant, full boost at any rpm. The boost can easily be feathered with the throttle to be less, more or anywhere in the middle. They basically turn a smaller displacement engine into one that performs like a strong running larger displacement engine.

An option I would consider is an LS swap which is blasphemous to mention in a Ford forum. So many have been done with so many vehicles that they have become very easy to complete. One of the baddest I have seen was done with a last gen Mazda RX7. An LS engine is so compact that it can fit in about anything.

 

[vroomzoomboom]

I'm honestly leaning towards putting a supercharger on it rather than a turbo. Really don't feel like doing the plumbing. So with that I think I've got the route I'm going when I do this. Oh, one more question. What about full time awd? What are your thoughts about adding the necessary equipment into this?

as mentioned, you will need to luck out finding a supercharger for a explorer, that or make your own mount, and intake. there is more to it then just that. upgrading fuel system (pump and injectors will be a must) possibly throttle body, it will need to be tuned with a wideband, this is just off the top of my head. im not trying to scare you away from it, just warning you so you dont get haft way into it then scrap everything because of time, money or both. if you do see it through all the way, it is a hell of a thing i tell ya! lol
as for awd, meh...... i converted to a 4406 transfercase and tossed the awd before i even turned the key. but i live up north. your in the south. will you really need it?

 

[410Fortune]

Full time awd sucks
It suck’s the fuel
It wears out your tires
And it eats power

Your rwd sport trax has the provisions for a front differential if you want to add a transfer case front differential and drivelines… it can be done rather easily
But to add the full time awd would be crazy

You can run a 4406 t case they come in 3 flavors manual shift, electric shift or electric shift with torque on demand control trac awd. I have yet to do the awd version but it could be done with some super wiring. This would be a part time awd setup

All 5.0 explorers are either rwd or full time awd
The full time awd is good for some but I personally do not like it and it is the first thing to go in any 5.0 truck I build, except for one… it was a Mazda pickup that was going to be used for ice racing he wanted the full time 30/70 split. I still think control trac awd would be a better fit in that truck too

 

[Tim72]

A Roots or twin screw supercharger will give you instant, full boost at any rpm. The boost can easily be feathered with the throttle to be less, more or anywhere in the middle. They basically turn a smaller displacement engine into one that performs like a strong running larger displacement engine.

An option I would consider is an LS swap which is blasphemous to mention in a Ford forum. So many have been done with so many vehicles that they have become very easy to complete. One of the baddest I have seen was done with a last gen Mazda RX7. An LS engine is so compact that it can fit in about anythe

Full time awd sucks
It suck’s the fuel
It wears out your tires
And it eats power

Your rwd sport trax has the provisions for a front differential if you want to add a transfer case front differential and drivelines… it can be done rather easily
But to add the full time awd would be crazy

You can run a 4406 t case they come in 3 flavors manual shift, electric shift or electric shift with torque on demand control trac awd. I have yet to do the awd version but it could be done with some super wiring. This would be a part time awd setup

All 5.0 explorers are either rwd or full time awd
The full time awd is good for some but I personally do not like it and it is the first thing to go in any 5.0 truck I build, except for one… it was a Mazda pickup that was going to be used for ice racing he wanted the full time 30/70 split. I still think control trac awd would be a better fit in that truck too

The only reason I thought full time all wheel drive was to limit wheel spin on the rear wheels and give the power to all 4 wheels. The control trac awd is that like stability control or something like giving power to the wheels that slip from the wheels that grip? Never heard of it to be honest. Is it too difficult to "wire" in? Will the computer need to be "updated or upgraded " in such a way? Down here, most people are tuning riders, building mustangs or chargers, and some occasional Audi's. But I've never seen anyone do what I'm wanting to do with this Sport Trac. That's why I'm "listing" different options I want to try or ask about before getting started. I want to do something that someone will go, "what the hell did he do to that Sport Trac?"

 

[Tim72]

The only reason I thought full time all wheel drive was to limit wheel spin on the rear wheels and give the power to all 4 wheels. The control trac awd is that like stability control or something like giving power to the wheels that slip from the wheels that grip? Never heard of it to be honest. Is it too difficult to "wire" in? Will the computer need to be "updated or upgraded " in such a way? Down here, most people are tuning riders, building mustangs or chargers, and some occasional Audi's. But I've never seen anyone do what I'm wanting to do with this Sport Trac. That's why I'm "listing" different options I want to try or ask about before getting started. I want to do something that someone will go, "what the hell did he do to that Sport Trac?"

94Eddie, my son suggested doing an LS swap to which I flat out said no. And told him I don't want to do what everyone else is doing. I want to be different and do something different. But yeah, I know I could do that, just want to be different.

The only reason I thought full time all wheel drive was to limit wheel spin on the rear wheels and give the power to all 4 wheels. The control trac awd is that like stability control or something like giving power to the wheels that slip from the wheels that grip? Never heard of it to be honest. Is it too difficult to "wire" in? Will the computer need to be "updated or upgraded " in such a way? Down here, most people are tuning riders, building mustangs or chargers, and some occasional Audi's. But I've never seen anyone do what I'm wanting to do with this Sport Trac. That's why I'm "listing" different options I want to try or ask about before getting started. I want to do something that someone will go, "what the hell did he do to that Sport Trac?"

 

[410Fortune]

Well the 5.0 explorers were built late 90s when gas was still cheap
They did not get a part time awd transfer case, what they have is full time awd. There are no wires no controls it is just a wet clutch. It sends 70% of the power to the rear and 30% up front all the time no matter what. What is not “used” is wasted energy in the form of heat. The issue with this I listed above, it eats fuel and front tires.
5.0 explorers (96-01) were shipped only rwd or awd.

Control trac,’torque on demand, fords “part time” transfer case is the one that sends power to the front when it detects slip.. control trac awd is possible because we can use a bw4406 control trac t case from an expedition behind your 5.0
This would require extensive wiring and the addition of a stand alone transfer case control Module

I have yet to do a control trac 4wd transfer case behind the 5.0 but it would be possible given all the right pieces

I have Built one sport trax to date that uses the stock 5.0 awd t case, it works fine, but it also gets about 10-12 mpg

The 5.0 sport tracs we usually build using a part time transfer case (bw4406 e shift from f150) are 2wd, 4hi and 4 low can get 15-18
Mpg.

My 2003 sport trax is a 5’speed manual with a clutch and a manual transfer case (bw 4406 m) gets about 18-20 mpg


Putting a Chevy ls engine into a sport Trac would be different for sure… the Chevy ls engine is powerful, Packaged small, and can be stuck into just about anything with just a few wires… but it also requires a bunch of custom work, mounts plumbing and exhaust.

Whereas your sport trac is nearly identical to the 96-01 Explorer that the ford 302 came in. So the 302 is a 95% bolt in deal
The Pushrod 5.0 in the explorer is the best of the best full roller engine with gt40 intakes, distributor less ignition, obd2 computer, short serpentine frontndress, metal power steering pump and 130 amp alternator factory
With exhaust headers cam aluminum heads fuel mods and tuning 360- 400hp crank is not that far away
The sky is the limit after that… it’s a small block ford… that’s why I ask, trucks use? And budget?

Lots to think about
The sport trax is a natural for the 5.0
Conversion
I have built several of them from mild to wild

 

[dvdswan]

Would love to do the 5.0L/5sp/bw4406e swap in mine. I have too many projects at home and then @410Fortune keeps plugging all these swaps and my head just keeps twitching with my conscious telling me, "Just do it and forget the rest." So little time so many needs. Secretly, I've been scouring FB and CL for a cheap 5.0 expo and dropping hints to the wife.

@Tim72, IMO do the swap first and drive it see how it feels. Just don't put in a tired drivetrain (5.0 and trans), it will make a difference.

 

[410Fortune]

Listen I can drive whatever I want
Any ford I choose
I have f350, e350, excursion, f250, full size bronco, bronco ii, rangers, explorers, sport trac all at my disposal.
My bronco ii has a 5.0
My sport trax has a 5.0

Where I live I often need to haul trash and fuel
So I need a truck bed 90% of the time
Driving a diesel flatbed 4 door f350 all the time is cumbersome. It’s big and slow, hard to park.
I have dogs, my border collie goes everywhere I go, so a back seat is a must.

My son is driving now but for the last few years we have hauled he and his friends all over. Bronco ii is small good for two people, dogs don’t like riding in the back there is no airflow
Rangers are awesome but with no cargo they ride bouncy and small cabs
The 01-05 sport trac is the perfect ford for me. So I picked one up for $700 with a near the end v6, blew up the v6, so I stuck a 302 in there (3ea 5.0 sport tracs in the family now)
Very cheap to own and operate
4 doors, Composite body, boxed frame, sunroof, roof rack, power everything, power down back window, and spring under rear axle… a truck that rides like an Explorer

No car payments in 30 years for me and 12 for the wife now (6 year loan to pay off her 07 FJ cruiser) My bronco ii and my sport Trac with the v8… well they don’t ever need anything really, just start run drive. Do it, you won’t regret it. The 302 is likely the most reliable ford engine made (300 i6 close second and the international 7.3 comes in third) you put a v8 and 3/4 ton trans in a ranger based vehicle and you have yourself a winning combination, what I call a “forever truck”
As you can see I am a huge fan of this setup
Driving old cheap junk with junk yard drivetrains has afforded me a great deal of freedom… with no car payments and very little needed for repairs, if I want a boat I can go buy a boat, bulldozer, tractor, g wagon, whatever I decide I “need” lol
I don’t have a 2025 bronco or jeep
Gladiator in my driveway.. but if I wanted one I could go get one…. Why? No debt, much of it due to my ability to keep our family Moving in cheap fords fixed with junk yard parts