Cast manifold on a 96

[5.Exploder]

Hello everyone,

I recently got a 96 Explorer XLT with the 5.0. I know quite a bit already about these engines and transmissions but, there are some things I'm not 100% positive about. As of now I have the transmission out (pulled in 4 hrs, not to bad eh), the exhuast system dropped and now I'm doing repairs while I get the transmission rebuilt. What I'm getting at is, I have a cracked passenger side manifold. I've been told the newer cast manifolds will bolt up just fine and I will just have to cap off the EGR port on the passenger manifold. I know the late 96-01's have the gt40p's and I have the gt40's with the internal EGR sytem. If anyone can give a true 100% answer based on experience from trying to do the swap would be extremely helpful.

 

[5.Exploder]

FYI The cast manifolds from the late 97-01 explorers and mountaineers with the gt40p heads WILL NOT fit on the 96 to mid 97 explorers with the gt40 heads. It has nothing to do with the egr type because that can be capped off. It also has nothing to do with the bolt pattern as it is the same. Its the angle of the spark plugs on the gt40 heads. They are angled forward and will hit the primary pipe that comes off the head. The cast manifolds are made to work with the gt40p heads only because the spark plugs on those heads come out straight. Hopefully this will help anyone who wanted to do this swap and wasn't sure if they would fit. So, if you have the gt40 heads you will have to do what I'm doing and buy the Torque Monster Headers.


UPDATE!!!! THEY DO FIT, YOU WILL JUST HAVE TO TURN YOUR PLUG BOOTS DOWN TO CLEAR THE MANIFOLD AND PLUG THE EGR PORT OFF WITH A 5/8" FLARE CAP FROM LOWES.

 

[FIND]

These will fit your application. They should flow about as poorly as the factory manifolds.

http://www.ebay.com/itm/1996-1998-F...Parts_Accessories&hash=item35bf620386&vxp=mtr

 

[5.Exploder]

I'm just going by what the tech at my local Ford dealership told me. I'm picking up the passenger side cast one to see if it's true.

These will fit your application. They should flow about as poorly as the factory manifolds.

http://www.ebay.com/itm/1996-1998-F...Parts_Accessories&hash=item35bf620386&vxp=mtr

 

[FIND]

The tech was correct in telling you that the cast manifolds that are available for the 97.5+ explorers won't fit. The GT-40P head has different plug angles. The manifolds will interfere with the plugs. You can also get those manifolds individually. The Dorman part number is 674357 for the passenger side. Ebay is the cheapest source for them though. Just search "96 explorer 5.0 exhaust manifold".

 

[1996BLKBauer]

The tech was correct in telling you that the cast manifolds that are available for the 97.5+ explorers won't fit. The GT-40P head has different plug angles. The manifolds will interfere with the plugs. You can also get those manifolds individually. The Dorman part number is 674357 for the passenger side. Ebay is the cheapest source for them though. Just search "96 explorer 5.0 exhaust manifold".

Not to take over the thread, but are the Ebay ones the same quality as the doorman part? I really hate skimping on engine parts, but it will most likely happen again, unless I can get a pair of Torque Monsters.

 

[FIND]

The dorman or atp ones are probably higher quality.

 

[5.Exploder]

Well I just tried a cast one on and it DOES fit with no problems. I just had to turn the spark plug boots down a bit to clear the manifold. So for anyone who wants to do the cast manifold swap THEY DO FIT!

 

[5.Exploder]

I just installed the passenger side with no issues. I have the 135° plug boots and just turned them down a bit to clear the manifold. So this is to clear the air, they do in fact fit. I just had to plug the egr port in the manifold seeing I have the internal EGR. I used a 5/8" flare cap from Lowes.

 

[5.Exploder]

And this is for anyone who is looking to do this on a internal EGR 5.0 like me and needs to plug the EGR port on the manifold you will need this part.

http://www.rjminjectiontech.com/products/metric-egr-plug