CHIEF Is Almost a 302!!!!!! 91 XLT SAS In the process of 302 and T-5 Swap!!

[95offroadx]

95offroadx
I found out that I was running WAY to far advanced on my timing, and I am going to test out my gas mileage again soon. I am willing to bet alot that my truck is going to get even better gas mileage now.

do you have any performance mods on the engine or is it just a stock 5.0?

 

[410Fortune]

wow.
I was wondering why the bolt went through the L&L mounts, why arent they welded?

Would love to see the new stainless mounts.
I assume you had to jump a wire from the power distribution to the engine harness, we made that mistake once before but figured it out fairly quickly.

You must have dual cats in CA to pass smog even with a single exhaust? I want to see your exhaust too please as you have a setup very similar to what I want to do.
I just think the stock explorer pipes hang down too low, but we shall see I guess.

Thanks for the info!

 

[RangerX]

You must have dual cats in CA to pass smog even with a single exhaust?

Man, I hope not. I just had a single high flow cat put in my F250 to replace both stock cats. My muffler guy showed me in some book that it was acceptable. I'll see in '06.

 

[410Fortune]

I am thinking they may be requiring it on his truck because of his conversion, dual cats were original equipment with his new engine.......

 

[Brett]

I assume you had to jump a wire from the power distribution to the engine harness, we made that mistake once before but figured it out fairly quickly.

Nope. He had a different NSS switch in the T5 than I expected. Simple fix.

Brett

 

[Chief34]

95offroadx
The motor is stock other than K&n cone filter, 9MM JBA plug wires, Custom Full length headers, high flow cat and Exhaust. It will be transforming relatively soon though. Another project

410Fortune
I passed the emissions test with only one cat....It is only because I was at the smog referee that he is making me put two. I only have to have two because the explorer came with two. If you go to a regular smog station they dont know the difference and as long as you have one and it passes emissions they dont know.

RangerX
It was good to see you again. I got to get together with you guys and do some wheelin. I will keep my eyes peeled for any club runs... Oh yeah, you shouldnt have any trouble come smog time.

Bretts the man! with a wire stripper

 

[RockRanger]

it was good to see you out at tds. Your swap looks like it came from the factory that way. Very clean job on it. Hopefully we will see you on a few more runs.

 

[Chief34]

Thanks Matt. I was glad to see you had wheels again. I felt bad for you guys over the fire and all. It would be fun to get together and wheel, so I will definately try to go next time there is a club run...

 

[Nitrous SSC]

Got any pics of it dirty yet?

 

[410Fortune]

Cheif I need some input from you.
I am using the 97 explorer uperr and lower intakes, they have the 90 degree elbow with EGR for the throttle body, everything works perfect, correct EGR setup, throttle cable and bracket, etc....HOWEVER the IAC valve is not going to clear my hood

So I am looking to get the 45 degree elbow, similar to what you have on your upper intake (94-95 Mustang) However I need to see the type of EGR it uses and also how you ran the throttle cable, what cable you used.
Also does this TB and elbow still have a IAC valve??

Pictures would be fantastic, I already read what yuou have and looked at the pics and they are helpful but I need more

I am down to the little stuff now, my 26" x 16" Ron Davis will be here SOON.

 

[93liftedXLT]

i just spent the last 2 hours read all 23 page's of this thread.this is crazy

CHIEF,I want your truck badly, ####ing awesome

 

[Chief34]

Sorry It took so long tio get back to you on this thread. The damn thing does not email me any more to let me know that someone has posted a reply.

Nitrous ssc... I dont have any of it muddy or anything.... There isnt a lot of mud in so cal. I do have pics posted of felxing and such though....

410fortune....
Let me know if you still have questions. I know you posted a while ago and I apologize. The egr on that year mustangs pulled exhaust up from the passenger side header. It enters directly into the back of the egr valve itself. The sensor on the egr is a different sensor as well. You can buy a special pigtail for about 15$ from ford motorsports that will plug into the stock harness and to the 94-95 style egr sensor. Everything should work.
For the throttle cable, I just modified the stock bracket that was on the mustang inlet adapter to hold the explorer stock throttle cable.
The mustang stuff still has an IAC valve. I will try to post some pics for you soon.

93 lifted,
Thanks alot! I am glad you like it.

 

[86caprirs]

Chief34:

That is one awesome setup you did there. The 4.0L and A4LD gave way in my truck, so i was just going to get new 4.0L and a rebuilt A4LD. But you have inspired me to do the 5.0L swap.I am going to stick with an AOD instaed of a 5 speed. I guess i will use your info and everyone elses input to make this swap easier for me. Thanks for the photo's on the way throughout your whole build up.

Shane

 

[410Fortune]

You might think about doing an Explorer 5.0L conversion since you want an automatic.
They came with the GT-40 5.0L and 4r70w automatic (AOD-EW)

I did this converion, well am almost done, see my signature

 

[86caprirs]

you can put the guts of a 4R70W into an AOD????I heard that somewhere but i forget who.

 

[Chief34]

410 fortune...
I am sorry I havent had a chance to get those pics on here for you. I Just bought a trick-flow adapter to replace the SVO one that I have on there which isnt legal in CA. I will be putting it on probably today. While I am out there I will get some pics of the IAC for you and post them right away. Again, I apologize for the delay.....

86Capris,
If you want an automatic... I would HIGHLY recomend using explorer 5.0 equipment. They do have the AOD with the 5.0 . The only reason I didnt use that equipment is because I wanted a 5 speed tranny. The explorer 5.0 package is usually a little more expensive to buy from junkyards or wherever, but I assure you it will be cheaper in the long run. There are a lot of things needed to purchase and modify to get the mustang package in there right. Good luck with it.

 

[killerx]

Hey

Sorry I bet you have gotten this question a lot but I didn’t find it on this thread. Well I was wondering what the company was that you used for the engine wiring harness and any others you may know of? Also I was wondering if this 302 that you’re putting in has a distributor or the EFI system. Did you change the ECU out for a different one? And any other electrical components or changes that I may need to do this to my ex. I’m really looking forward to my new 302 in the ex. Thanks again for such a great post.

Killerx

p.s. all the Montanans up here think I’m nuts for doing this to an ex but I love my truck so what ever. Thanks for being so inspiring.

 

[rookieshooter]

That was some thread. CONGRADULATIONS !!!!!

 

[410Fortune]

Killerx,

Brett from this forum (moderator) built the wiring for cheifs truck.
He's my wrenching buddy, and we tackle these wiring projects together when we have time.
Cheif did use the EEC-IV 5.0L harness with the distributor. The harness is a plug and play unit, with the original truck ends on the harness to make it plug directly in.
In this thread Cheif talks about this briefly and notes how the harness was left bare so he could taylor it to fit his engine bay to his liking.

The 5.0L conversion has been done alot! So there really are no surprises, there are a number of ways to do the wiring and each truck really varies from one another BIG TIME. I personally researched the conversion for the last 5 years or so, including being involved in one in person and several over the internet. So when I did mine I really did not run into one single issue that I did not know I was going to have.

So keep researching on this and several other forums. There is a wealth of info, and you can simply Google "Ranger 5.0L" and read for days

The latest craze in the 5.0L conversion world is the use of the late model Explorer 5.0L drivetrain, because well Ford made it to fit the Explorer, which in turn makes it fit your truck 10 times easier.


Have fun!

 

[Chief34]

410 fortune.......

Well said! Thank-you very much.