Lastly, I’m just throwing this out there, as most of you think it is my solution, and I want to be certain on price, since I have already done so much.
I'm not one of those yet. But I can still be convinced.;D
I'm a huge fan of the Explorer setup of course, and have recommended it for years. But you already seem to have lots of air flow (well, some of the time at least).
However, it could still come down to water flow too, and right now you're just running a stock pump in a stock orientation. Which I don't think is as effective as the Explorer setup.
And at the same time, if it was me, even though you want to change just one aspect at a time to be sure you know what fixes the issue, if I had all that apart up front I would be installing a FlowKooler or similar high-volume pump at the same time.
Of course, that's because I would likely be putting a new water pump on the old setup anyway. No matter if I wanted a high-flow pump or not. I just don't trust old junkyard pumps in general.
What am I looking at financially for the explorer front dress. $900, plus fan clutch and fan?
Should not be that much, but it definitely climbs quickly. The assembly will likely come with fan and clutch anyway. If you get it from sandmann here, you should get it all.
And yes, the clutch "might" be toast from an old setup, but I trust the old clutches more than I do the old pumps. Can't remember how many who've done the swap have had to replace the clutch.
Pricewise, I've seen over the years anything from $200 to $600 all-in. If you get a pump for about $60 (standard) to $110 (Flow-Kooler) you could still be into it for way under the $900 you were thinking.
Unless prices have gone way up since the last time I looked?
Can I run it with my Ron Davis radiator? Same shroud?
Absolutely. Many of us are...
Mine is a stock radiator layout (our triple-bypass version) and aluminum RD shroud (based on the stock design though) and works well together. Yours should too.
Also about how long does it take to install? Is it pretty straight forward?
Now that's something I've never paid much attention to. But with your recent experience at yanking things and putting them back, you should be able to do it in an hour!
For me though, probably take all weekend because I like to stare at parts until they clean, paint and reinstall themselves.;D
As usual then, your results may vary.
Probably others here have a better idea of what it takes though.
Could I possibly go to a pick a part and remove it from an explorer, or is getting the complete system from a vendor the easiest?
Either way. Whether it's "easier" one way or the other though, depends on how much you like to play around in the junkyard.
I actually do like grubbing around in the boneyard, but still prefer buying one. I got mine from sandmann about 10 years ago now I think.
He's got it down to a science, but if you do it yourself just make sure you get EVERYTHING from the Explorer front!
You'll need the main brackets, the harmonic balancer (more on that in a minute), the front cover, thermostat/water neck, any other little nick-nacks and ALL of the bolts. The fasteners are very Explorer-specific, just like the rest of the stuff.
Depends too on if your junkyards still have Explorers and Mountaineers.
Back to the damper, if your current engine is a 50oz imbalance modern 5.0 setup, you just put the Explorer damper on and go.
If it's an early 28oz crank/block, you can use the Explorer damper after you have DamperDudes (or anyone that can do the work) re-balance the setup to your engine.
Or you can use the original factory damper for your engine (assuming it's close to a Bronco damper) and add this pulley:
https://www.wildhorses4x4.com/product/Custom-Crank-Pulley-Bronco-302-Explorer-5-front/bronco_pulleys to make it all play nice together.
Depends on what you have on there now.
Paul