Turbo SOHC to Turbo 5.0 V-8 AWD

[slammed98z]

Even the "improved" rear guide assembly still has no metal backing on the traction side to keep it from fracturing. One member recently experienced a bent valve on cylinder #3 when his chain slipped due to broken rear guide assembly.

The 99 and later models with the returnless fuel system have the fuel pressure regulator mounted in the tank and a fuel pressure damper mounted on the fuel rail. The fuel pressure runs 60 to 65 psi at engine start and any time engine is running.

There were significant wiring changes implemented in 1998. What year PCM do you plan to use? The 1999 PCM will have a PATS interface that the 1996 won't have. There are other differences in the OBD-II firmware. I suspect it will be simpler to stick with the 1996 PCM since it's hardware should support the V8. Some of the PCM connector functions changed between 1996 and 1999 when VIS was eliminated.

Thank you for the information, i might have to pull the whole under hood harness and go and get a PCM, Engine, and Under-hood harness from a 96-97. I had already swapped the under-hood harness to the 99, mainly because of the mountaineer front headlight Assembly.

The Pcm i have is a 99, along with the engine harness, and under hood harness, the body harness is a 96. The main reason i was going with the 99 stuff is to add the creature features that my base 96 does not have.

I will have to get a return fuel rail for the motor also.

 

[slammed98z]

I think I may have my Oil Pan Still....I put mine in a 1st Gen, so I use a Dual Sump.

My pan is from a `97 GT-40P (build date of 10-96)

Let me know if you need it.

Ryan

Im going to try to knock out the damage on the pan, if i cannot get it fixed ill send ya a pm.

 

[CDW6212R]

That should be a fun truck when you finish it.

The 99+ wiring is different under hood as you know, look at the Power Distribution Box. The 98 trucks got a lot of upgrades, as you mentioned as creature comforts.

I suggest buying a 98 under hood V8 harness, plus the PCM and fuel injector rails. That should almost plug into your 99 body harness, you can work out minor issues like the headlights etc. Since you will need PCM tuning, the return style fuel system is easier to work with, and turn off PATS if you like. Regards,

 

[slammed98z]

That should be a fun truck when you finish it.

The 99+ wiring is different under hood as you know, look at the Power Distribution Box. The 98 trucks got a lot of upgrades, as you mentioned as creature comforts.

I suggest buying a 98 under hood V8 harness, plus the PCM and fuel injector rails. That should almost plug into your 99 body harness, you can work out minor issues like the headlights etc. Since you will need PCM tuning, the return style fuel system is easier to work with, and turn off PATS if you like. Regards,

My Sport is a 96, which is the one that the engine is going into. The main reason for doing the 99 under hood V-8 harness was to keep the factory wiring for the headlights. It does not really matter which harness i have to get, i would prefer to stick to the 96-97 harness so i don't have to deal with swapping the body harness or any other things not to mention mess with the PATS system.

So the list of things i need to get from the Junk Yard goes as follows:

96-97 Under-hood harness
96-97 Engine & Transmission harness
96-97 PCM
96-97 Fuel Rail

I guess i will just have to adapt the 96-97 Headlight wiring to the 98+ mountaineer front headlight assembly.


As for now i am stuck on what i can do with the swap. I need to pickup a oil pan, and the other stuff listed. Another Question. DID ford ever make a explorer (95-01) without A/C?

 

[CDW6212R]

I'd check with Eric about his 302 Sport, he swapped to a Mountaineer headlight and front end. He can tell you what wiring changed for those. They all have AC, and there were about four oil pans. Ford made them in steel or aluminum, with and without the oil level sensor. I wouldn't try to re-bend a pan, they don't lay level on the block typically after being bent. I have two spares, one in steel that I didn't like the way it set on the block, and it was just set on the ground gently from a picker.

Look into the wiring changes from 97 to 98 302 harnesses. They may be close enough to use either way, check an electrical diagram for that. The connectors will all be alike, as time went by Ford put more relays in the PDB, instead of hanging separately by themselves from the main harness.

Hunt a good DVD for the wiring of the 96 versus 98 or 99 trucks, you will need those quite a bit.

 

[slammed98z]

I'd check with Eric about his 302 Sport, he swapped to a Mountaineer headlight and front end. He can tell you what wiring changed for those. They all have AC, and there were about four oil pans. Ford made them in steel or aluminum, with and without the oil level sensor. I wouldn't try to re-bend a pan, they don't lay level on the block typically after being bent. I have two spares, one in steel that I didn't like the way it set on the block, and it was just set on the ground gently from a picker.

Look into the wiring changes from 97 to 98 302 harnesses. They may be close enough to use either way, check an electrical diagram for that. The connectors will all be alike, as time went by Ford put more relays in the PDB, instead of hanging separately by themselves from the main harness.

Hunt a good DVD for the wiring of the 96 versus 98 or 99 trucks, you will need those quite a bit.

Pm Sent on the pan

 

[99SportX]

Awesome project dude! I would like to turbo my explorer someday so I am going to follow this one for sure.

My V8 swap stuff came from a 2000 Mountaineer and I swapped the headlights along with it. I used the body harness from my 99 sport, dash harness from the mounty, and engine bay harness from the mounty (dash harness because I wanted the EATC and Message Center). I am not sure how the 96 wiring will interact with the 99 wiring but there are multiple ways to go about it. You could convert your whole truck over to the 99 setup, or you could convert the mounty stuff back to 96. I am not sure what would be more work as each alternative would require modifications to different parts of the truck. I personally would go 99 with it all but that is just what I am used to. lol You would only have to buy a body harness from a 99 sport. You could even use the 4 door body harness and just modify using parts from your 96 body harness. You have all the parts in the donor to run the 99 electronics.

I am in the process of going 2wd. My chassis is now true 2wd, but I still have the AWD transfer case installed. I have not had any traction issues on dry ground but then again, I am not turbo'd. The next step is to figure out the transmission end of things.

 

[slammed98z]

Well im off to the junkyard to get the engine harness, under-hood harness, PCM, and fuel rail. hopefully that will be all i need to get the engine into the explorer.

 

[Turdle]

Well im off to the junkyard to get the engine harness, under-hood harness, PCM, and fuel rail. hopefully that will be all i need to get the engine into the explorer.

I am almost sure you need the pats module, and ignition switch with keys also. PCM, pats and key are all coded. UNless you turn off pats with the xcal,
however, I think you need the proper key and pats module to even get that far. I am not sure about this--you might check it out.

 

[Spdrcer34]

My pan is Aluminum, with no Oil Level Sender in it.

Ryan

 

[blk mk8]

there are some cast ones and steel ones. this should be cool swap and turbos are always good too

 

[Jakee]

I keep finding myself looking for V8 AWD wrecked explorers. Thanks a lot man.

 

[CDW6212R]

I keep finding myself looking for V8 AWD wrecked explorers. Thanks a lot man.

Jake, for your truck you would want 4WD spindles from a 2001+ Sport or Sport Trac. Your rotors are 1" larger, which is due to the spindle. So if you do go that way, get the spindles separately, mine were $100 that I put on my 99. Night,

 

[slammed98z]

I keep finding myself looking for V8 AWD wrecked explorers. Thanks a lot man.

Got some progress done, no pictures. Got the front diff, spindles, and ect swapped on the front end. Got the wiring switched out from the v-6 to the v-8 underhood harness.

Found a pan locally. Hopefully should get the motor in tomorrow.

 

[slammed98z]

Got the front diff up and everything ready for the engine to drop in. Just waiting on a oil pan.

Another thing i thought of while i was working on the front end, what driveshaft did you guys use when you swapped the 5.0 awd setup into your sports?

 

[CDW6212R]

Try for a good OEM type 302 AWD front shaft if you can swing it, they are not cheap when new. Those will be the smoothest, and most people have vibrations from any u-joint type shaft. The next best thing should be a double cardon shaft, but having one made will be nearly $200 I believe.

 

[99SportX]

The stock 4 door V8 AWD shaft will work. The front shaft from a V6 explorer is about 1" longer I believe. I had my my driveline shop shorten my V6 one down to V8 length because the rubber boot on the cv was still intact.

Just use the one from the donor, you will be fine.

 

[CDW6212R]

What he said, Eric made it simpler. I was thinking of the AWD choices, and what people do when those go bad. I first had a single joint shaft made, and it vibrated a good bit. Then I bought a used AWD shaft, which has lasted 77k miles or so. The guys who swap to the bigger BW4406 TC usually end up with a double Cardon type shaft, made for it, a hair longer yet.

 

[slammed98z]

Finally have some progress, Took a week to locate a junkyard that would pull off a oil pan, most of the junkyards wanted to sell me a whole motor. Got the underhood harness stuff swapped, tested it out and everything seems to be working. Going to the Junkyard later today to pickup the oil pan, should have some progress pictures tonight.

 

[2000StreetRod]

progress update?

How's the engine swap progressing?