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

[Chief34]

And finally a shot from above......

 

[Chief34]

So I also, Had to modify my ac bracket because the new shorter water pump does not stick out and bolt up to it. Here is a ahot from before... You can see the missing holes that are no longer needed.

 

[Chief34]

Here is a shot after I torched it.

 

[Chief34]

And here is a shot of it after it was all cleaned up and painted........

 

[Chief34]

I also removed the old tubes that use to feed the heater core. This is where the Temp sensor used to bolt into. I am going to get a different fitting to go in place of it which still has provisions for the temp sensor. This one will come straight up out of the motor and the heater core hoses will go stright into it from there. Otherwise there is to much interference with firewall, if you try to hook it up from the stock location. I will get pics of the new fitting later....

 

[Chief34]

here is what it looked like after removal...

 

[Chief34]

The stock hoses for the power steering hooked right up to the 5.0 steering pump...........

The nuetral start switch that goes on the clutch pedal plugged right into a connector that was under the dash already. It was just capped off. That made that easy...

 

[Chief34]

Here is a shot of the chrome pedals in....

 

[Chief34]

here is a shot of the clutch master and resevoir from outside. The master went right into a hole in the firewall that had a little plate bolted on to block it off. Just unbolt the plate and bolt in the new clutch master. Then just plug it into the harness under the dash....

Then just drill one hole in to one of the "impressions" that is already made for you in the plate for the resevoir. The resevoir bolts right up into the stock location. Looks factory!

 

[Chief34]

oh yeah and I slo got my windshield wiper motor back installed. Its coming around folks....


I'll have more later!

 

[TravisC]

so do you have an estimated date on when the final product rolls out? I wanna see this thing smoke em!!

Looks great!

 

[Holty]

AWESOME PROJECT! good work, i love it!

 

[Dolphan]

Great job, great looking truck, and fun to watch the progress, via your updates. Can't help but think this project was just an excuse to up your posts - LOL

 

[Superswamper44]

I just want to hear it lol good luck with the install

 

[Chief34]

Well, An estimated date? I would have to say about 4 weeks. I wont see my harness for probably 1 1/2 to 2 weeks and that gives me 2 more weeks to finish up all the little details. The only other major things after the wiring are My electric fan that is about $360.00 and My radiator Which will probably be $250.00-$400.00 depending on where I decide to get it or if I have one made custom. The Custom dual exhaust is already taken care of. I went and did some Bobcat work at my buddys house over last weekend. So When I am ready I'll just take the truck down there to his 4X4 shop and have him do the exhaust and maybe a couple other things too I might even send back my James duff long tube headers and just have my buddy make custom ones

Holty... Thanks you very much

Dolphan... I was rollin' when I read that

SuperSwamper44: Heh whats that mean? You just want to hear the engine when I am done? I'll be sure to get an audio of me roasting the tires for you. But A quick one that rubber aint cheap, as you probably know very well

 

[Superswamper44]

yes i bought my first J**P in April.. right now it's on 31" A/T's and only a body lift and a shackle lift the 2nd day I was out rideing around stil messing with it you know " getting the feel for it " did like 10 dough nuts in a row got it all on film but the price was more than i had to get them replaced lol i had fun though..... by the way I'v seen your explorer a long time ago on the fourm and now that I have seen u post so i know you haven't moved to a diffrent fourm......... If you don't mind me asking how much $money$ invested in your X? looks great by the way lol good luck on the rest of the install

 

[Chief34]

Super Swamper,

I wasnt sure what you meant when you asked how much do I have invested in my X. In the swap part or a lifetime total....

But here is a rundown.

I painted it about a year and a half ago... My grandfather in law owns a paint and body shop down here and I worked out a deal with him. They have one of the best painters I have ever seen. He is very meticulous as well. They are not cheap though, If someone just brought a 4 door X in to them and said paint it complete they would charge about $4500 bucks for everything. I stripped the entire truck myself inside and out. I removed everything! Windows, moldings, seals etc...
1) They Installed and uninstalled the windshield, and back 2 quarter panel windows
2) They Shaved all the holes for emblems and body moldings for me.
3) Did all the prep work.
4) Painted, and cleared it.
5) then color sanded it and buffed it.

He only charged me $1700

Next I lifted the truck. A freind of mine owns a big 4X4 shop down here and I went to his house and did some equipment work for him in trade for my lift. So all I paid for the lift was
1)$420 for 2 national soft ride springs,
2)$450 for my Solid axle,
3)$1200 for My swampers and wheels
4)$500 for 4 fox shocks
For a grand total of about $2600 for the lift. They had my truck for over 2 months though.
I later recieved the resevoirs for my shocks as a christmas gift from my mother, and just last month recieved 2 more shocks with resevoirs from her for my birthday, so those didnt cost me anything.

That leaves us with the swap which isnt finished yet but I did make a break down of cost so far in the post somewhere and when It is done I will make a final cost and product review post. So to stop being long winded I would have to say I have about $3300 total without the swap. Not to shabby, the key is doing everything you can yourself.

 

[Superswamper44]

wow man ..........Thats alot i just wish i had connections like you lol.... But i can't say nothing about the cost i'ma bout to buy me a D44 or a 9" thats gonna be around $1,200 but yeah thats what i get for getting a J**p lol .... BTW i was talking about the hole cost from like the 1st day you got it... thanks for the info

 

[madmoose]

Have you stoped working on this thing how come you went with the t-5 tranny? I'm doing the same swap and am thinking of using the m5 tranny out of the full size ford 1/2 ton trucks it has hydrolic clutch sleeve and i think it's the same size as the mazda tranny. Do you think that the tranny will hold up to the stress? Other than that she looks really good!!! Keep up the posts its helpfull for people like me, also how much $ was the wiring harness?

 

[93exploder]

where did that battery holder come from ? that is awesome !