DP96XLT
Well-Known Member
- Joined
- November 29, 2019
- Messages
- 123
- Reaction score
- 49
- City, State
- New Berlin, WI
- Year, Model & Trim Level
- 1996 Explorer XLT 4WD
Hey guys, I figured I would post this because I will honestly admit I have never ran across this kind of issue on any engine/car I have owned/worked on...
First off I have a 43k mile 1996 Explorer XLT 4dr/4wd with the 4.0l OHV v6 engine. Basically like new, did plugs, wires, PCV valve, air filter, etc.
I originally posted about it when I got it back in November of last year and have been doing stuff to it since, but I have always had abysmal gas mileage and power has really lacked. It was so bad the wife even asked if I could do something like adding a supercharger to it. (yeah, I married the right woman)
But, honestly, no matter how easy on the throttle I was I couldn't get more than 210 miles to a tankful (basically around 12mpg). With all my upgrades I was able to eliminate any sort of "drag" being the issue (new brakes all around, all synthetic fluids, checked hubs/axles/bearings/etc). I checked the throttle position sensor, coolant temp, intake temp and everything else and it all checked out fine. Also no diagnostic codes, no misfires, per scans the fuel trims were in-line and in general it seemed to run smooth and even enough. Always had that weird exhaust/engine sound that I was told made the Cologne engine kind of a unique thing.
Now, I changed out the muffler system for a Gibson cat-back. It changed the exhaust tone, but didn't change the power/gas mileage (I didn't like the tone with the Gibson chambered muffler so I switched to a Borla XS straight through). I switched to a K&N intake (got it for $125 new off Amazon so why not), again, no change.
So, about the only part I didn't change was the ignition coil. I did the standard spark test and it was nice and bright enough on all 6. But, as a last hail-marry I decided to put on a new coil. Found an Accel 140035 coil on ebay sold by Accel themselves for $50. Decided since it was basically cheaper than a Ford OEM coil, why not.
Got it in, 10 minutes later it was installed and upon starting it up I could tell it made a world of difference. Immediate start, even smooth idle (smoother than before), exhaust tone was totally different and in general I was surprised. Took it for a drive and it is a totally different truck. It has decent power and it is no longer a dog. The one issue I have is that the tranny seems to be "lazy" but I do realize being a OHV it isn't meant to rev to the moon all the time and the transmission programming is optimized to utilize the massive torque-band the engine puts out. I (and I am sure a lot of others) are just used to powertrains downshifting as soon as you WOT regardless, where-as this setup at times most certainly determines you are in the right gear already and refuses to downshift on a pedal to the floor request (there is an on-ramp downtown that is a decent 25-30 degree upward grade and if I am going fast enough onto the ramp when I WOT it won't downshift and rides out the current gear even locking up the torque converter while in WOT as an example).
I drove a few tank fill-ups and I am up to 18-19mpg. And that is with being somewhat aggressive with the throttle at times. I also noticed the exhaust tone changed quite a bit and I might have not minded the Gibson muffler after all since it seems somewhat quieter than it was before even with the Borla.
I can say it is far from the dog power-wise it was. I would put it on-par with most torquey v6s. I did have a buddy do some tests on the coil (he has the equipment to test coils and get readings while firing) and he said it was putting out like only 6-8k volts. Said it most certainly was probably an internal issue (figured it was cracked potting from age) since it looked fine on the outside and I as well as he tested the resistance and all coils were "in range" per spec.
One other thing I noticed before the coil pack was whenever I had the headlight on and put on the directionals the engine would change rpms in time with the directionals (putting on the hazards were even more noticeable). Once I swapped the coils that weirdness went away and no kind of current draw affects the way the engine runs.
Moral of the story, coil packs are cheap, if you checked everything else, swap it out.
I will do another write-up on the stereo system upgrades (nav headunit, amplifier, subwoofer), charging system upgrades (2-gauge and 4-gauge wiring along with 240amp alternator), lighting upgrades (12-gauge hot-wire harness and higher output bulbs) all with in-depth info on how/where I ran wires, connected into the stock power distribution block and in general made everything seem as if it was there from the factory.
First off I have a 43k mile 1996 Explorer XLT 4dr/4wd with the 4.0l OHV v6 engine. Basically like new, did plugs, wires, PCV valve, air filter, etc.
I originally posted about it when I got it back in November of last year and have been doing stuff to it since, but I have always had abysmal gas mileage and power has really lacked. It was so bad the wife even asked if I could do something like adding a supercharger to it. (yeah, I married the right woman)
But, honestly, no matter how easy on the throttle I was I couldn't get more than 210 miles to a tankful (basically around 12mpg). With all my upgrades I was able to eliminate any sort of "drag" being the issue (new brakes all around, all synthetic fluids, checked hubs/axles/bearings/etc). I checked the throttle position sensor, coolant temp, intake temp and everything else and it all checked out fine. Also no diagnostic codes, no misfires, per scans the fuel trims were in-line and in general it seemed to run smooth and even enough. Always had that weird exhaust/engine sound that I was told made the Cologne engine kind of a unique thing.
Now, I changed out the muffler system for a Gibson cat-back. It changed the exhaust tone, but didn't change the power/gas mileage (I didn't like the tone with the Gibson chambered muffler so I switched to a Borla XS straight through). I switched to a K&N intake (got it for $125 new off Amazon so why not), again, no change.
So, about the only part I didn't change was the ignition coil. I did the standard spark test and it was nice and bright enough on all 6. But, as a last hail-marry I decided to put on a new coil. Found an Accel 140035 coil on ebay sold by Accel themselves for $50. Decided since it was basically cheaper than a Ford OEM coil, why not.
Got it in, 10 minutes later it was installed and upon starting it up I could tell it made a world of difference. Immediate start, even smooth idle (smoother than before), exhaust tone was totally different and in general I was surprised. Took it for a drive and it is a totally different truck. It has decent power and it is no longer a dog. The one issue I have is that the tranny seems to be "lazy" but I do realize being a OHV it isn't meant to rev to the moon all the time and the transmission programming is optimized to utilize the massive torque-band the engine puts out. I (and I am sure a lot of others) are just used to powertrains downshifting as soon as you WOT regardless, where-as this setup at times most certainly determines you are in the right gear already and refuses to downshift on a pedal to the floor request (there is an on-ramp downtown that is a decent 25-30 degree upward grade and if I am going fast enough onto the ramp when I WOT it won't downshift and rides out the current gear even locking up the torque converter while in WOT as an example).
I drove a few tank fill-ups and I am up to 18-19mpg. And that is with being somewhat aggressive with the throttle at times. I also noticed the exhaust tone changed quite a bit and I might have not minded the Gibson muffler after all since it seems somewhat quieter than it was before even with the Borla.
I can say it is far from the dog power-wise it was. I would put it on-par with most torquey v6s. I did have a buddy do some tests on the coil (he has the equipment to test coils and get readings while firing) and he said it was putting out like only 6-8k volts. Said it most certainly was probably an internal issue (figured it was cracked potting from age) since it looked fine on the outside and I as well as he tested the resistance and all coils were "in range" per spec.
One other thing I noticed before the coil pack was whenever I had the headlight on and put on the directionals the engine would change rpms in time with the directionals (putting on the hazards were even more noticeable). Once I swapped the coils that weirdness went away and no kind of current draw affects the way the engine runs.
Moral of the story, coil packs are cheap, if you checked everything else, swap it out.
I will do another write-up on the stereo system upgrades (nav headunit, amplifier, subwoofer), charging system upgrades (2-gauge and 4-gauge wiring along with 240amp alternator), lighting upgrades (12-gauge hot-wire harness and higher output bulbs) all with in-depth info on how/where I ran wires, connected into the stock power distribution block and in general made everything seem as if it was there from the factory.
