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

[Chief34]

There is a thread on here somewhere.... Anyway, I had a small leak that I neglected and it ended up causing the front bearing on the imput shaft to go out, wich in turn broke third gear and the rest of it..... I dont think it would have broken if not for that, BUT I did rebuild it with High alloy gears from Astro Performance and It has held up great!!

'even though it's working out....... The cost of the Advance Adapter and the dificulty with replacement "jeep" housings to mate this up in a 4X4 situation are a real downside. If I was to do it all over again, I would have used a Ford Full size tranny and t-case.

The idea was to keep my driveshaft lengths the same (to save money and to make things easier) and keep my electric push button t-case (because its awesome not getting out to go into 4X4) But I ended up having to modify the driveshaftr lengths anyway... I do still have my push button though!!! That I do like!

 

[AchromicSkin]

so its been a couple years on this thread since anyone has posted.
I have a couple questions cuz this is something that i am highly considering if I don't do the stock OHV Turbo build.
on the motor you went with, would you recommend using a '94-95 motor instead of the earlier year like you used?
Also, you went through a lot when trying to get the 4X4 to all mount up properly, what do you think the difference would be since I want to stick with 4X2?
I prefer more of a long travel front end with a beefy winch. Ive had full size 4X4...and thats what i prefer when 4X4...when it comes to the smaller Ex, i want it to have some balls, long travel front end, and full size rear end and suspension to be able to tow a decent amount
I'm not too savvy yet welding...but has been something that I have wanted to get into for quite a long time...so I have a feeling the Ex will be one of my first projects with all my dads tools I get to steal and the Mig my friend has. Ive been wrenching on cars for a little while now, but noting needing fabrication like this...thats the difference the tuner world to the off road world. haha

Thanks for the time!
and PROPS Chief for the build! thats a mean ass 4X4!!

 

[Chief34]

double post....

 

[Chief34]

First of all...Hello,

I'll try to answer your questions in the order you asked them.

I am really glad I used the Earlier year engine for a couple of reasons. There are far more of them out there if you need something, or a replacement. The Computer is alot more modification freindly and I knew I would be supercharging and tuning it. If your in California... I would say use the 94-95because it will make life easier at the smog ref... Anywhere else, or if you can register it somewhere where there isnt any smog testing then use the earlier motor. I could help you out with the radiator clearance if its an issue for you and the air inlet elbow is an easy addition to get around your A/C box... If you do this I even have some parts I could sell you for your swap, like 96 up Explorer headers to make fitment a breeze.

In a 2wd situation, the swap will be a piece of cake. Run it hard with the
T-5 and dont worry about it. Just dont miss a 3rd gear shift under full throttle and you probably wont break it. I have never done that, but that is supposed to be the weak gear. Anyway, They are not hard to rebuild at all. I tackled mine when It broke and I had never been inside a transmisison before. You can download a rebuild tutorial online for free and its easy. A full rebuild kit is only like 185-200 bucks. Astro performance makes Awesome upgradeable Hard parts that will make it bulletproof if you wanted. I used the High alloy gear sets when I rebuilt it and it has held up great even to my supercharger. With the 2wd you'll have the complete stock T-5 trans (half of mine is a jeep t-5 cuz of the Advance adapter) and you can even get an upgraded mainshaft that is much stronger if you prefer, or need it. They even have a 26 slpine mainshaft that allows you to get the 11" clutch on there.

This is long-winded, sorry. heh heh. Anyway, you wont re-gret doing a V-8 swap I promise, plus you can always turbo or supercharge your V-8 as well. If you have any other questions or need advice, let me know. Ill be glad to help. Also there are a TON of online resources for a 5.0 and almost NONE, in comparison for turbo-ing the OHV.

Good Luck!!

 

[AchromicSkin]

oh dont worry about being "long winded" haha I just took a couple days to read every post on this thread...haha.
I'm one who will sit here for months and months researching everything I need to do a project before I start...and at the moment I don't have all the tools to start...so I might as well get as much knowledge in as possible
with my truck being a '93...and wanting to make it smog legal if I do go the V8 swap...I am forced into going a 93-95 stang...but what about the 2G Ex V8? I was thinking of tuning purposes...the stang motor has a distributor and the Ex V8 has a coil...if i'm not mistaken...but my biggest concern is staying 5spd...has anyone done a 2G Ex V8 swap with a T5?
If I'm stuck using a stang motor to use the T5 then that gives me an excuse to pick up a 94-95 and drive it around then start pulling the Ex apart get all the parts ready and prep the Ex for insertion, go to a junkyard and get another stang harness so I can get as much work done on the Ex before I loose both driveable vehicles. haha.

I havent put $$ into "building up" the Ex yet...so I'm trying to play out all my options before I bring all the tools over and start cutting up my truck and get my mind set on a design.

Thanks for the input! and when it comes time for the work...i'm in Riverside, maybe 45 mins from you...so Id like some input if you ever get a chance

 

[Chief34]

Well, The explorer V8's only came with the auto "AODE" tranny. Thats exactly why I didnt use one. Plus the junkyards want a fortune for them compared to the stang engine which is MUCH more plentiful. I got my engine, tranny and wiring harness for 1200 bucks from a junkyard up in Ontario. alot closer to you. Riverside is about 1.5 hrs from me.

Anyway, if you put a T-5 behind the Explorer V8 you will have a check engine light and not be able to pass smog. Also that computer is not tuner freindly either. I would strongly recomend going with the stang engine.

You can use the early engine series. You would need to tell the smog ref that your engine came out of a 93 mustang and you just have to make sure the vaccum and egr is set up correct for that year. They wont know the engine is a 87-93. *my engine is actually from a 90 mustang....shhhh, nobody knows * There are only a few differences being egr and vaccum routing. I have diagrams for the different years....

The Only advantage to using the 94-95 engine is that it has the curved intake elbow that will clear your A/C box and that it has the shorter front accessories. Both of which can be fixed easily. The only thing you have to do when you go that route is to go to the smog ref with the straight style intake and throttle body. After he signs off on you you can install the elbow and 94-95 throttle body so you can put your A/C box together. Next time you have to smog you should be able to leave it because you can go to any old smog shop. They will use the info on your referee sticker and just look for the obvious like a smog pump etc.... They wont know about the intake elbow because they are 50 state legal.

 

[AchromicSkin]

ok I was really thinking about just going strait to a '94-95 motor so I didn't have any fabbing to do for the shorter water pump, etc...like you did.
I have been looking through Craigslist and auto trader and I can get a running '94-95 for $1500-3000 so I'm thinkin id have fun driving that around during the tear down and modifying stage of the Ex.
I'm not a super savvy "transmission" guy...so what complications am I looking at dropping a stock '94-95 T5 into mine. I'm already 5spd...but are the trans different clutch wise...i remember you were having to do some modding on your trans...but i didn't know if that was because you went Auto to 5spd...or cuz of differences in the Ex clutch to the stang clutch.

 

[Chief34]

Your golden with your stick to stick conversion! you already have the shifter, pedals, steering column without a tranny shifter, etc, etc.... Whats great is that the explorer uses a hydraulic throwout bearing for the stock tranny.

All you need to put that in your is to get a Hydraulic throwout bearing from McCleoud Industries.... Its about $300. the part number is above in a previous post. Then with a little bit of 4an braided you can hook it right up to your factory master cylinder. I dont know about the driveshaft exactly but chances are you will have to have it shortened and you could have then put the correct end on it for the u-joint that goes to the T-5 and then it would bolt right up. shouldnt be that expensive.

The biggest problem you will probably have is the shifter location. It will probably be back into your center console some.... You will have to measure. The ULTIMATE would be to use a Tremec T-5. More money but the ultimate in a 2wd scenario. It is stronger and best of all is it has like 3 different locations for the shifter, depending on how it is assembled. You can move the shifter further forward on it and it will be right where you need it. Otherwise, you could do a little modifying of your center console.

 

[AchromicSkin]

awesome info on the Hyd TO Bearing thanks! I will read up a couple more times what you did and see if I can figure it out. haha

shifter location - I was thinking about having a friend of mine fabbed me a shifter arm to set the knob where I want it...but do you think the shifter will actually be sitting under the center console, or are you just implying the "throw" of the shifter will interfere with the center console? I don't mind too much fiberglassing up a new center console if I have to. I used to do a lot of custom stereo work so fiberglass boxes arn't new to me. haha.

drive shaft - i figured i would have to have one made...this is something Ive never priced out...whats a rough cost that a shop charges to make a driveshaft?

body lift - is a 2"-3" body lift something I should really plan on for this swap? Honestly I'm not a fan of them...if I lift i go suspension...but if I have to for a swap...then maaaybe...haha.

 

[Chief34]

Wow, sorry for the delay!! Ive been crazy busy lately trying to get ready to move! Houston here I come!!


1) The Hydro bearing is by far the way to go... very clean and simple to
install...

2) The shifter will definately be IN the Center console... Off the top of my
head probably right about the cupholder or maybe even just behind it!
If you can do fiberglass then thats PERFECT! Just plan on modifying or
making a center console...

3) The Driveshaft shouldnt be a big deal... Probably $75-$250 to have a
shop modify and balance it. It depends a little on how much you need
to do to it, but I would stress on it too much. Youll most likely need it
shortened and a different end put on it so it will mate up to the tranny.

4) You can do it without the body lift, but it makes things real tight
depending on what you want to do with your radiator and fan(s)

5) Plan on fiberglassing your A/C box to make room for your Throttle
cable... Its easy. I just made a cover out of thin aluminum because at
the time I didnt know how to fiberglass.

Any other q's just ask!!!!

 

[Claytonc]

Thought I would out my 2 cents worth in now. This is an awesome thread I learned a bunch. Thanks for that.
I was wondering about putting the engine in, you dropped it in without the tranny or with. My question is, did you have problems getting the engine and tranny to line up properly or since you used a manual trans it bolted right up?

 

[Chief34]

well... i put the engine in without the tranny because it was easier. the tranny bolts right up to the engine, but i had to modify the
crossmember slightly...

 

[breakman]

Good job dude

 

[Chief34]

lol... let me know if you have any q's ! i would be glad to help...

 

[John_Rock]

Howdy neighbor! :wavey:

 

[Chief34]

Whats up!!! hey yall..... keep posted, Im gonna try and get the garage cleaned up this weekend and finish working on this Fiberglass interior on my truck!! stay tuned...lol

 

[mr cribb]

I read all 25 pages... and I have an idea for the a/c part.. just delete the whole box and keep the heater. I mean with a 302 you'd have more than enough air flow to make up for the a/c... just my 2 cents.

and another footnote, the f150 5 speed lines up in the factory hole location on a 1st gen explorer as I have read on here.

Now if I could only get the wife to agree to the swap....

 

[twisted91]

Been awhile since been on here, but new thing happening in 2 weeks!! Inspired by a very well built now TEXAS owed X!! Got lots of info an I must say that is one hell of a built explorer!! Doin mine with a bronco 5.0L and an AOD! Cheap!!! Free parts an got full size axles on trade!! 38s here I come!!!

Nice job there chief !! Fitting actually

 

[Chief34]

THANKS! Yeah I havent been working on the X in a long time, but its funny because I JUST cut rings out of mdf for my speakers last night...lol. So for now I am back on the fiberglass project. Lets see if I can actually get something done... Ill post pics! Good Luck with that project it sounds fun! Let me know if you have any questions...

 

[Insanejuggalo]

Hey chief I plan on doing this swap hopefully soon if every thing goes as planned but my question is where the shifter comes out of the floor did you have to cut that or was that already there?