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Cooter's Explorer 5.0/4R70W Swap

1buckeyefan1

Sr. Member
Joined
Sep 21, 2017
Messages
632
I have to say this is a spectacular thread, especially the pictures at every stage. This serves as an invaluable guide for those to come. I'm undertaking the same swap and would not have attempted it without threads like this. I hope I can pay it forward too when the time comes!

Sent from my Pixel 3 using Tapatalk
 

duffymahoney

Contributor
Bronco Guru
Joined
Apr 26, 2015
Messages
2,561
I have to say this is a spectacular thread, especially the pictures at every stage. This serves as an invaluable guide for those to come. I'm undertaking the same swap and would not have attempted it without threads like this. I hope I can pay it forward too when the time comes!

Sent from my Pixel 3 using Tapatalk

Agreed, great build thread.
 
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OP
Cooter_76

Cooter_76

Sr. Member
Joined
May 18, 2004
Messages
863
I have to say this is a spectacular thread, especially the pictures at every stage. This serves as an invaluable guide for those to come. I'm undertaking the same swap and would not have attempted it without threads like this. I hope I can pay it forward too when the time comes!

Sent from my Pixel 3 using Tapatalk

Thanks! Happy to contribute anything to this site, which has provided so much info over the years.
 

lagbolt

Sr. Member
Joined
Jul 18, 2012
Messages
577
Cooter what’s your plans for the air filter/ intake hose?


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Cooter_76

Cooter_76

Sr. Member
Joined
May 18, 2004
Messages
863
Lately I've been working on the passenger side firewall area. Things are getting crowded.
- Ran new rubber hoses to the heater core and installed the heater valve. The original heater valve cable was too short, so I used a generic choke cable from the parts store. Not real happy with this solution, because it's ugly, and doesn't seem to be strong enough to fully close the valve. I may need to tweak this a bit, unless someone has a better option.

49172977513_5bafe56d19_z.jpg


- I purchased a throttle cable bracket from JSmall. It's a great solution that fits really well. I may have to take some material off the bottom, because it's making contact with the heater coolant tubes. I just set the upper intake on top of the lower without the gasket, so maybe it will clear once everything is assembled properly.

*EDIT* The bracket cleared everything just fine once I had the manifold secured properly.

49173459866_1f18d9a3f9_z.jpg


- There's a tube that's now on top of the throttle body. I believe this connects to the oil fill tube on the passenger side valve cover to act as an intake for the PCV circuit(?). Curious if there's a way to rotate it 180 degrees to make it easier to route the tube and provide some extra clearance for the transmission dipstick.
49173556251_2ddf4fa79a_z.jpg


Here are a couple more pics of how things are shaping-up in this area:

49172977503_61f3a7c817_z.jpg


49172977498_9404369939_z.jpg
 
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904Bronco

Contributor
Bronco Guru
Joined
Sep 28, 2004
Messages
5,758
Loc.
San Martin, CA
Put a large Phillips screwdriver in the TB fresh air tube and it should rotate for you. Press fit.
I have only had one that distorted when I got little "animal" with it...
 

JSmall

Bronco Guru
Joined
Feb 18, 2004
Messages
3,223
- I purchased a throttle cable bracket from JSmall. It's a great solution that fits really well. I may have to take some material off the bottom, because it's making contact with the heater coolant tubes. I just set the upper intake on top of the lower without the gasket, so maybe it will clear once everything is assembled properly.

[/img]

Please let me know. I can make a change if I ever have more produced if that is going to be a clearance issue. For some reason, it is not with my set up.

Build is looking good :cool:
 
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Cooter_76

Cooter_76

Sr. Member
Joined
May 18, 2004
Messages
863
Please let me know. I can make a change if I ever have more produced if that is going to be a clearance issue. For some reason, it is not with my set up.

Build is looking good :cool:

Thanks Jaromy, I'll keep you posted!
 
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Cooter_76

Cooter_76

Sr. Member
Joined
May 18, 2004
Messages
863
Spent some time this morning modifying the gas pedal to accept the Explorer throttle cable, based on a photo I saw somewhere here on CB.

49178364316_b84dfde6fa_z.jpg


49177873833_a5ea387e39_z.jpg


49178364391_ea9ffe9f0b_z.jpg
 
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Cooter_76

Cooter_76

Sr. Member
Joined
May 18, 2004
Messages
863
Put a large Phillips screwdriver in the TB fresh air tube and it should rotate for you. Press fit.
I have only had one that distorted when I got little "animal" with it...

Ah, the joys of modifying a 23-year-old engine to install in your 46-year-old vehicle:
49178689786_7fbcd0f036_z.jpg


Don't know if my next step is to try to drill-out what's left of the old tube, or try to pick up another throttle body somewhere.
 

jbawall

Contributor
Full Member
Joined
Jul 14, 2004
Messages
314
Loc.
Edgewood, Washington
Oh man! That stinks. Mine just moved pretty easy, but it is a new one so maybe that is the difference. New ones are a little hard to find, not terrible, they are out there. Used ones can be pretty rough though, which is why I bought a new one. Do you think you can get the remnants out? Maybe you can just bend up a tube to replace it with.
 

Hazegray

Sr. Member
Joined
Aug 10, 2004
Messages
795
Maybe a lil' finesse was in order! ;D

Try heat gun, melt some wax around it and bolt extractor to get that out...
 
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Cooter_76

Cooter_76

Sr. Member
Joined
May 18, 2004
Messages
863
Maybe a lil' finesse was in order! ;D

Try heat gun, melt some wax around it and bolt extractor to get that out...



Funny enough, I tried a heat gun. I was expecting it to start to bend if I went too “animal”, but it just cracked open.


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904Bronco

Contributor
Bronco Guru
Joined
Sep 28, 2004
Messages
5,758
Loc.
San Martin, CA
Drill it out and tap the hole for 1/8" pipe thread, use 90* elbow male pipe > nipple...

Sorry it happened, probably too many heat/cold cycles over the life of the TB.
 
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Cooter_76

Cooter_76

Sr. Member
Joined
May 18, 2004
Messages
863
Small victory! I think this is the first time I've ever used an extractor successfully.

49204458301_a6dccdef76_z.jpg


Used a piece of 3/8" brake line to replace the damaged elbow. Fits nice & snug.

49203972278_5053129f00_z.jpg
 
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