96 Explorer Roller Motor with 91 Mustang EFI

[Chief Master Sergeant]

The Explorer motor is being rebuilt as I type this. My intention is to run the 91 Mustang EFI intakes, as I have the Bronco already wired for it. Any issues I need to be aware of? The Explorer used the odd distributor, with coil pack off to the side. Will by 91 Mustang Distributor work?

 

[sykanr0ng]

It should work, but why do it that way?
People have been using the Mustang electronics and harnesses on the Explorer intakes for years in Broncos and other vehicles.

 

[bigmuddy]

No worries !

 

[Chief Master Sergeant]

It should work, but why do it that way?
People have been using the Mustang electronics and harnesses on the Explorer intakes for years in Broncos and other vehicles.

Mainly because the upper intake was MIA when I grabbed this engine. This is all pretty new to me, so I wasn't sure it would work. Thought my Mustang harness wouldn't work with the Explorer stuff. I guess I could try to source the upper intake. Is it a better? Sorry, I'm learning.

 

[sykanr0ng]

Mainly because the upper intake was MIA when I grabbed this engine. This is all pretty new to me, so I wasn't sure it would work. Thought my Mustang harness wouldn't work with the Explorer stuff. I guess I could try to source the upper intake. Is it a better? Sorry, I'm learning.

Yes, it is a better intake, which is why the Mustang guys were changing theirs to them.
There are a few small changes you would need to make but since it was done so much a few years ago it is all well documented.

 

[Broncobowsher]

Might have to keep the mustang sensors. I think a few of them changed.

But the real basic question, can you drop a mustang EFI intake and distributor onto a '96 Explorer 5.0? Yes, no problem at all.

As stated, the Explorer intake is better than the mustang version. Lots of mustang people upgrade the mustang with an intake swap. Keep all the mustang parts and use just the castings from the Explorer.

Hopefully you got all the Explorer accessory drive as well. That is the best accessory drive for a Bronco.

 

[Chief Master Sergeant]

Might have to keep the mustang sensors. I think a few of them changed.

But the real basic question, can you drop a mustang EFI intake and distributor onto a '96 Explorer 5.0? Yes, no problem at all.

As stated, the Explorer intake is better than the mustang version. Lots of mustang people upgrade the mustang with an intake swap. Keep all the mustang parts and use just the castings from the Explorer.

Hopefully you got all the Explorer accessory drive as well. That is the best accessory drive for a Bronco.

Yep, I got it all. Now debating whether to use the Explorer Power Steering Pump or buy the bracket to use my existing Saginaw. Thanks everyone.

 

[sykanr0ng]

Yep, I got it all. Now debating whether to use the Explorer Power Steering Pump or buy the bracket to use my existing Saginaw. Thanks everyone.

What tire size?
Some people do have trouble with the Explorer pump and others have no trouble, but IIRC few to none have had problems with less than 35 inch tires.

 

[Broncobowsher]

The biggest issue is usually the wrong fitting screwed into the pump. There are several fitting that fit, but don't work (they trip the pressure relief valve inside). Lee Powersteering makes a fitting that does work. Start there.

 

[Chief Master Sergeant]

What tire size?
Some people do have trouble with the Explorer pump and others have no trouble, but IIRC few to none have had problems with less than 35 inch tires.

Running 35s

 

[Chief Master Sergeant]

The biggest issue is usually the wrong fitting screwed into the pump. There are several fitting that fit, but don't work (they trip the pressure relief valve inside). Lee Powersteering makes a fitting that does work. Start there.

I'll check it out. Thanks

 

[Chief Master Sergeant]

A couple of questions for those who have done the Explorer motor install.

1. Do I use the stock Bronco motor mounts? I assume so, but want to ask before I go out and buy something.

2. Will the stock Bronco starter work? No transmission changes, so I assumed I could use the backing plate and original starter. Again, I assumed so, but wanted to ask.

I have the motor on the stand, rebuilt. Now I need to button up a few things and buy the last pieces I need.

 

[Broncobowsher]

1; yes. The small block fold has the same bolt pattern regardless. The different motor mounts are for the different chassis.

2; yes. The starter bolts to the bellhousing. You are aware that the early flywheel (or flexplate) will be wrong for the Explorer motor? It will bolt up, everything will mesh perfect. But part of the rotating balance of the engine is in the flywheel. About '81 Ford changed how much of the external balance is in the flywheel. The engine will be severely out of balance if you use the wrong flywheel.

 

[Chief Master Sergeant]

1; yes. The small block fold has the same bolt pattern regardless. The different motor mounts are for the different chassis.

2; yes. The starter bolts to the bellhousing. You are aware that the early flywheel (or flexplate) will be wrong for the Explorer motor? It will bolt up, everything will mesh perfect. But part of the rotating balance of the engine is in the flywheel. About '81 Ford changed how much of the external balance is in the flywheel. The engine will be severely out of balance if you use the wrong flywheel.

Thanks! Yeah, I bought a new flywheel and clutch for it. Just wasn't sure if the metal insert (?) and starter from the stock Bronco engine was used.

Probably overthinking a lot about this. Thanks again

 

[Sporto]

Hey Chief,
What harness are you running? Mustang or Explorer? The lower intakes on the two are different, and there are some mods that you need to make if you have the Explorer lower to work with the Mustang harness. If you have the Mustang lower then you should be ok hooking up the connectors. Also, if you're running the TFI distributor from a Mustang you will definitely need the Mustang harness since it has the proper connector for it.

I have done this once before with a cross between a Mustang computer/harness and an Explorer engine. It worked, but there were some differences that we had to account for, so try and get a Mustang (or equivalent) lower intake if you can.

Rich

 

[Chief Master Sergeant]

Hey Chief,
What harness are you running? Mustang or Explorer? The lower intakes on the two are different, and there are some mods that you need to make if you have the Explorer lower to work with the Mustang harness. If you have the Mustang lower then you should be ok hooking up the connectors. Also, if you're running the TFI distributor from a Mustang you will definitely need the Mustang harness since it has the proper connector for it.

I have done this once before with a cross between a Mustang computer/harness and an Explorer engine. It worked, but there were some differences that we had to account for, so try and get a Mustang (or equivalent) lower intake if you can.

Rich

Thanks Rich. I have the Mustang lower and upper and the Ron Francis harness for the Mustang EFI. I'm about ready to drop her in place. The engine shop said the motor was extremely clean. Excited to get this in and running again.

 

[Sporto]

Thanks Rich. I have the Mustang lower and upper and the Ron Francis harness for the Mustang EFI. I'm about ready to drop her in place. The engine shop said the motor was extremely clean. Excited to get this in and running again.

Sounds like you have it all locked down. Should be easy to get together and running then. Keep us posted!

R