My 5.0 swap with details

[Hossexplorer]

Has anyone used the BW 4406 electric shift in a 1st gen Explorer?

I am thinking about trying to find a BW4406 and modify the electrical plug at the transfer case so I can still use my stock shifter buttons.

 

[jrgaylor]

It actually clears the dash and console right now, but I don't think it would have fit without the body lift. I am going to shorten the shifter and maybe bend it slightly to be more comfortable.

Have you seen the gear banger they have for the early broncos?

 

[Hossexplorer]

Have you seen the gear banger they have for the early broncos?

Yes! They look great! I contacted them about making one for an Explorer/Ranger setup and they were glad to build one with some measurements from me.

 

[DymondD]

Those brackets will fix your problem. Just installed them. Moves the bracket to the front side of the cross member web.

 

[The_Phoenix]

Hey Dude did you ever get this thing running

 

[zundap750]

I'm curious also. Is it running? I'm thinking about a V8 swap into my 98 2wd.

 

[NickRunge1995]

so i heard the 5.0 from the explorer will bolt up directly is this correct???

 

[Hossexplorer]

UPDATE:

I have not been active on here for a long time, but I never gave up on my Explorer 5.0 swap. Here it is all finished!

I used the factory 4.0 radiator by moving it toward the front of the car . I had to cut a small amount of the core support and move the A/C condenser in front of the core support. I used the factory mustang upper radiator hose and the factory explorer lower hose.

Radiator
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A/C condensor
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For the air intake tube, I bought a kit that fit an 04 Suburu WRX and cut to fit into my stock air box with a K&N filter. The mass air flow sensor is the stock explorer which is working great with the 5.0 Mass air computer.
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[Hossexplorer]

It is kind of hard to see in these photos, but I used a remote oil filter kit from summit racing and mounted the filter on the passenger side. I also replaced the steering box and added a drop pitman arm along with a steering stabilizer.

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[Hossexplorer]

For the fuel system I used the factory Explorer fuel pump and filter. I bought Dorman Ford fuel quick disconnect ends and a roll of nylon fuel hose and pressed my own fuel lines.

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[Hossexplorer]

I ended up using an NP205 transfer case which I am happy with, except it is very heavy. I tried to fit an NP208 and BW1356, both hit the frame rail and I was not willing to notch the frame. The factory Ford Explorer speedometer cable plugged in the NP205 without mods and is accurate without the needle bouncing.

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[Hossexplorer]

I ended up using an NP205 transfer case which I am happy with, except it is very heavy. I tried to fit an NP208 and BW1356, both hit the frame rail and I was not willing to notch the frame.

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[Hossexplorer]

I changed out the automatic brake pedal assembly for a factory explorer manual pedal set. For the clutch setup, I used a 1993 explorer clutch master cylinder, 1989 bronco clutch line, and 1993 Ford f150 6 cylinder external clutch slave cylinder. The reason you need to use the 6 cylinder slave is it has a smaller diameter than the 1986 F150 NP435 has. The explorer master does not have enough force to push a 1" bore slave. I believe the one I used has a 15/16" bore.

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And here are the shifters all bent and cut to shape.

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[Hossexplorer]

For the exhaust, I had to use 1970's car manifolds. They tuck close to the block. From the y-pipe, it becomes 3" single with a flowmaster muffler. It has a nice rumble around town but is quiet on the highway.

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[Hossexplorer]

For those wondering how it does without overdrive, it does just fine as a daily driver. I have 3.27 gears with 32" tires. It runs just over 2,000 rpm @60mph. Oregon hwy speed limit is 55 so it works out great.

Overall, I am very happy with the swap. It is really fun to drive and very comfortable to me.

Was it easy? NO.
Would I ever do it again? NO.
Was it worth it? YES!

I'll try to answer any questions you have
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[mr cribb]

Nice.