I'm going to have a lot of Iraq money to spend. '03 EB

[jbsnyder85]

I didn't do too much to my Ex before I left, on account of the whole the Army pays less than nothing issue, but I'm deployed and have almost no expenses besides my car payment and I'm planning on spending more than I should to get my truck up to par. My plan is to squeeze as much MPG out of the 4.6 as I can. Fortunately I can make it quite a bit beefier and still accomplish that goal. I've been browsing this forum for about a month now and I've learned a lot, at least 3/4 of which has been from aldive's gas quest. Besides what I've read on here I really don't know an amazing amount about performance upgrades. What I'm looking at right now:

MAC CAI (http://www.hensonperformance.com/Productsfta.html)
JBA Headers (http://www.jbaheaders.com/detail_shortyV.asp?id=1678S)
Henson Performance tuning (with wideband sensor?)
Silla Radiator (http://www.car-stuff.com/carparts/fordexplorer20022005sillasilla2434a44812.html)
Magnaflow Cat-Back (http://www.car-stuff.com/carparts/fordexplorer20022005magnaflowm66157181.html)
BBK Intake Elbow (is this a plenum?) (http://www.car-stuff.com/carparts/fordexplorer20022005bbkb4517601.html)
BBK Throttle Body (http://www.car-stuff.com/carparts/fordexplorer20022004bbkb4517001.html)

Now for the questions (numbered for easier response)
1) What else do I need to upgrade on the ignition system? I've seen coil packs for the 4.0 but none specifically for the 4.6 Explorers. However I've seen plenty of coil packs for the 4.6 Mustang GTs. Will these work with my Explorer? I've heard that I can widen my spark plug gaps when I'm running a better ignition system. Will I see any gain from this? I'll leave it stock
2) How much will I gain by swapping the fan for an electronic fan? I know there's quite a bit of parasitic loss from the fan. How do I get a new belt for this, if I do cut out the fan? Will my ECU compensate for this loss by metering out less fuel, or will the only benefit be the freed-up HP?
3) Will intake manifolds / TBs / plenums from 4.6 Mustangs work on my Explorer? If it's not a straight swap, how big is the difference? Can it be fairly easily adapted to work?
4) Are the parts that I've picked out the best choices? When I swap them in will there be any glaring bottlenecks that you can think of?

A good friend of mine has a fully stocked garage and knows far more about auto work than I do and he's willing to help, so I won't hurt too bad with the work. We're both fairly smart people, I think we'd be able to figure out some simple adaptations if it comes to that. Thanks in advance for the help. This forum makes me so homesick for my truck. I can't wait to get back and void my warranty. Just over a year left!

edit
list updated!

 

[kars85]

I just did 3 big upgrades on my '03 4.6 EB within the past month. They included a MAC intake, Magnaflow Catback, and Tuning by James @ Henson Performance.

Our X's have coil-on-plug. The stock ignition is good as is and spending the big $$'s on COP upgrades doesn't reap much (if any) benefit.

There's a lot of debate about how much benefit e-fans give. From what I hear, as long as your mechanical fan hasn't seized, the only time it should actually engage the clutch is when it gets above the thermostat setting. Also, another argument is the extra load e-fans put on the alternator actually equalizes the difference in parasitic drag from the mechanical fan. For me there is too much gray area to justify the cost and PITA factor of putting it in. E-fans have improved drastically over the years in terms of reliability, but if the fan motor goes out, you're screwed. At least with a mechanical fan you can keep going indefinitely if the clutch seizes.

Your mods look good as they're all personal preference. I'd drop the ignition wires and maybe put that money into a underdrive crank pulley. Give James @ Henson Performance a call. (205) 531-0598. Not only is he a class act guy, but is a site sponsor and much more active in the forums than Doug is. Again, your call.

 

[jbsnyder85]

Hah yeah jtsmith recommended him to me earlier and sold me easily with the story of that over-email tuning gig they pulled.

Regarding the ignition wires, so is increasing the current to my spark plugs with the intent of messing with the gap size pretty much a pointless endeavour?

 

[E.B. Cornburner]

Regarding the ignition wires, so is increasing the current to my spark plugs with the intent of messing with the gap size pretty much a pointless endeavour?

Until you start messing with power adders such as a supercharger, turbo, or nitrous, it is.

As long as there's enough voltage to jump the plug gap, more voltage is going to accomplish nothing.

Changing the plug gaps isn't something I'd recommend either.

 

[blown03]

Until you start messing with power adders such as a supercharger, turbo, or nitrous, it is.

As long as there's enough voltage to jump the plug gap, more voltage is going to accomplish nothing.

Changing the plug gaps isn't something I'd recommend either.

+1 don't believe the market hype you see about how good brand X of spark plugs or ignition products are. Unless your current ones need to be replaced you're not going to see any benefit.

 

[Fantasymon]

My Advice:
1) Come back from Iraq safely
2) Put the money in a Roth IRA and savings
3) Don't throw money into your Explorer
4) Retire Happier
:

Oh and I might add my reasoning....mods are an addiction: once your start, its hard to stop...

 

[Turdle]

My Advice:
1) Come back from Iraq safely
2) Put the money in a Roth IRA and savings
3) Don't throw money into your Explorer
4) Retire Happier
:

Oh and I might add my reasoning....mods are an addiction: once your start, its hard to stop...

You said it.

This place is crazy--

 

[Kyle0614]

x3^^ i'm on my second modded explorer will it ever stop ?

 

[jah81592]

Sir,
My recommendations will be similar but with a few modification in brand (unless there is obviously loyalty). I would recommend A MAC intake simply because they are known for good quality and the fitment is great on the Explorer. As far as adding a muffler I would recommend a full cat-back system because when you just add a muffler you mainly add sound and nothing more. As far as your coils, go here to see that I offer coils for your ride (Accel part# 140032) as well. I also offer underdrive pulley sets and custom tuning for your ride. Remote tuning is an option. I am a one stop shopping with a specialty in the Explorers. I would definately consider the ASP underdrive pulley set as they are an excellent addition to your parts quest in making great horsepower. Good luck modding. Oh an huwahhhh- I was 101st Airborne!

 

[jbsnyder85]

Thanks for all the help. jah81592, I browsed around on hensonperformance and there's quite a bit I want on there. As for getting addicted to mods, well, college will be paid for, so for the next 4 years at least I don't have to worry too much about how I spend my supplemental income. And the girlfriend is pretty loaded so that's nice too.

I like a lot of the ideas from aldive's thread, especially the theory that small changes will add up. A lot of my ideas come from my buddy that has messed with his Hemi Ram way too much too. I'm already planning on flushing my xmission, xfer case, and diffs and replacing with Royal Purple. Should I see ANY gain from this? He also switched to an aftermarket radiator and claimed to gain a bit of MPG from that. Any benefit? And nobody I've talked to, even the Ford enthusiasts in the unit (my unit commander, by the way, has 4 mustangs in various states of disrepair and has done all the work himself) has been able to give me a straight answer whether or not aftermarket throttle bodies and plenums for 4.6 mustangs will fit.

 

[jah81592]

I offer the C&L (not on my website), the upper plenum and throttle bodies will work-email me for the specifics. Flushing the trans and diffs,etc with synthetic won't hurt a thing at all, may potentially pic up a few hp and mpg. As far as replacing a rad and increasing mpg? That is a new one on me, not saying it cant be done but I haven't heard of it before. The underdrive pulley set would be a better investment than the radiator and the hp and torque (roughly 15hp/20lb.ft torque) would definately be the results without any negatives(cooling and charging).-j

BTW- I offer throttle bodies and different cat-backs as well. If interested I can put together a package deal. It is common for me to do so.

 

[jbsnyder85]

I offer the C&L (not on my website), the upper plenum and throttle bodies will work-email me for the specifics. Flushing the trans and diffs,etc with synthetic won't hurt a thing at all, may potentially pic up a few hp and mpg. As far as replacing a rad and increasing mpg? That is a new one on me, not saying it cant be done but I haven't heard of it before. The underdrive pulley set would be a better investment than the radiator and the hp and torque (roughly 15hp/20lb.ft torque) would definately be the results without any negatives(cooling and charging).-j

BTW- I offer throttle bodies and different cat-backs as well. If interested I can put together a package deal. It is common for me to do so.

The theory he spouted is an aftermarket radiator cools the engine better, thus allowing it to run cooler and combust denser air.

Are underdrive pulleys safe on daily drivers?

edit
Almost forgot. Low rolling resistance tires- gimmick or gas-saver? Is there a loss of traction?

 

[wood1]

Aftermarket rad increasing HP? I'm no automotive engineer but back in the day we use to throw in a cooler thermostat for that. If you aren't already taxing your cooling system then an aftermarket rad would be a waste of money IMO. And the addition of an electric fan does increase mileage and power. Ask the mileage guru...

http://www.explorerforum.com/forums/showthread.php?t=44372&highlight=quest

He's running a 4.0 SOHC but many of the princials are the same.

 

[jbsnyder85]

Aftermarket rad increasing HP? I'm no automotive engineer but back in the day we use to throw in a cooler thermostat for that. If you aren't already taxing your cooling system then an aftermarket rad would be a waste of money IMO. And the addition of an electric fan does increase mileage and power. Ask the mileage guru...

http://www.explorerforum.com/forums/showthread.php?t=44372&highlight=quest

He's running a 4.0 SOHC but many of the princials are the same.

Oh I have had his thread bookmarked for a couple weeks now and I'm trying to borrow as many feasible ideas as I can.

 

[blown03]

I offer the C&L (not on my website), the upper plenum and throttle bodies will work
.

Really, that's good to hear. I know when I had my old 2V GT back in the day the upper plenums were a pretty popular mod. It's cheap and led to decent gains on the GT's, I'd imagine it would do the same for the exploders.

 

[SnookMan]

I offer the C&L (not on my website), the upper plenum and throttle bodies will work-email me for the specifics. Flushing the trans and diffs,etc with synthetic won't hurt a thing at all, may potentially pic up a few hp and mpg. As far as replacing a rad and increasing mpg? That is a new one on me, not saying it cant be done but I haven't heard of it before. The underdrive pulley set would be a better investment than the radiator and the hp and torque (roughly 15hp/20lb.ft torque) would definately be the results without any negatives(cooling and charging).-j

BTW- I offer throttle bodies and different cat-backs as well. If interested I can put together a package deal. It is common for me to do so.

I've heard that the underdrive pullies are a no-no for daily drivers. That it slows the water pump down to a crawl, causing overheating, and that the alternator spins to slow to charge a truck with accessories. My buddy has warned me away from them over and over and he's a mustang/crown vic guy. Curious, have you been having success on cars you've worked on with them?

 

[Thelt]

A bunch of mods to increase fuel economy seems self defeating to me. You are going to have a hard time saving enough gas to offset the cost of the mods. If that is what makes you happy though go for it. I do second the guy who said to use your Iraq money on something more constructive, down payment on a house or something?

 

[wood1]

I've heard that the underdrive pullies are a no-no for daily drivers. That it slows the water pump down to a crawl, causing overheating, and that the alternator spins to slow to charge a truck with accessories. My buddy has warned me away from them over and over and he's a mustang/crown vic guy. Curious, have you been having success on cars you've worked on with them?

I put march underdrive pullies on my 5.0 back about...er.. 12 years ago?

I had to put the factory alternator pulley back on, the damn thig would kill the battery if you left it there idling. (took a while mind you)

Never had any cooling issues though.