Explorer 5.0/4R70W swap questions

[JK]

I've done the searching, and I'm pretty versed on options, so this is more of a "What do you think would be the best for my situation" advice request. It's almost time to drop the Explorer setup in and I'm trying to gather the last of the parts. Going to a 2001 5.0/4r70W, pulling out the 302/3 speed. First item, radiator. I would like to go to a nice, but cheap, radiator with trans cooler that will fit with the 5.0/explorer fan and not present alot of issues. I've read alot about the Champions, and the Summit specials. Does anyone have a direct Exploder drop in with an auto trans that might be able to provide me a part number? There are about 200 threads with 500 different part numbers, so I was hoping to find someone who had done the swap and picked up a Champion or Summit radiator to help me out. Second, headers. I don't really want to pony up $600 for the BC Ceramics. Anyone have experience with this swap and the Bronco Hut headers for the GT40P's? Any better options in that price range (or cheaper)? I plan to get the ZF adapter ordered, and the harness is headed to EFI Guy for a rework, and will be an OBDII setup. Any other obscure parts that I might be overlooking?

 

[garberz]

I don't have a suggestion for you about the radiator. I haven't had good luck with aluminum radiators. The V-6 Explorer radiator is the only one I would consider. I have a stock copper/brass radiator in excellent shape, so I plan on just using a cross over pipe for the lower hose.

Exhaust manifolds, why is everyone so quick to dismiss the stock exhaust manifolds. I haven't swapped my motor in yet, "P" heads, but I put the Explorer manifolds on my old 302 along with an entire new exhaust system. It sounds great and there are no leaks (there never will be). If I ever crack one of those, I'll just replace it with another stock one. I don't think it would be very hard to source. I'm running a stock 98' Explorer motor. Headers vs. stock manifolds, won't make a bit of difference in mileage or power. Non that would be over the top noticeable.

I reworked the harness myself along with several calls and emails to EFI guy. He's taking care of my EEC. I hope to make the swap soon. I have most of the other stuff done already.

You'll need to figure out your throttle cable and some type of conversion for your power steering HP hose. Lee's Power steering makes the pump/AN-6 adapter. Get that ordered up ASAP. You have the return less HP fuel system, You need to figure out how to get the stock Explorer fuel pump and regulator into your tank. There's a handful of guys working on this swap right now, so most of your Q's have been dealt with. Just ask.

Mark

http://lee-powersteering.com/

 

[JK]

I don't have a suggestion for you about the radiator. I haven't had good luck with aluminum radiators. The V-6 Explorer radiator is the only one I would consider. I have a stock copper/brass radiator in excellent shape, so I plan on just using a cross over pipe for the lower hose.

Exhaust manifolds, why is everyone so quick to dismiss the stock exhaust manifolds. I haven't swapped my motor in yet, "P" heads, but I put the Explorer manifolds on my old 302 along with an entire new exhaust system. It sounds great and there are no leaks (there never will be). If I ever crack one of those, I'll just replace it with another stock one. I don't think it would be very hard to source. I'm running a stock 98' Explorer motor. Headers vs. stock manifolds, won't make a bit of difference in mileage or power. Non that would be over the top noticeable.

I reworked the harness myself along with several calls and emails to EFI guy. He's taking care of my EEC. I hope to make the swap soon. I have most of the other stuff done already.

You'll need to figure out your throttle cable and some type of conversion for your power steering HP hose. Lee's Power steering makes the pump/AN-6 adapter. Get that ordered up ASAP. You have the return less HP fuel system, You need to figure out how to get the stock Explorer fuel pump and regulator into your tank. There's a handful of guys working on this swap right now, so most of your Q's have been dealt with. Just ask.

Mark

http://lee-powersteering.com/

My radiator has a bit of an issue cooling my current 302. It does it, but starts to warm up a bit at idle on hot summer days. I've already addressed shroud, new fan, new thermostat, new pump, so I think an upgrade is in order.

I currently have a set of Hookers on the 302. Are you saying to run the factory Explorer manifolds? Not sure if they are coming with the donor, but I'll check that out. Any issue with fitment in an EB with the Explorer manifolds?

I have the BC throttle cable now so that shouldn't be an issue. For PS, I have Hydroboost/4X4X2/Saginaw. I might be able to source an adapter for the current Saginaw HP fitting on my HP hose to the Explorer PS pump. For fuel pump, I planned on doing a frame rail mounted inline pump and an adjustable pressure regulator. I'm only running a rear tank, so I think that should work.

 

[surfer-b]

Just run the factory manifolds, they fit perfect.
Radiator- I just used a factory AL replacement from "Radiators for Less" on ebay, never had any cooling probs and have been running it all summer here in the SE heat and humidity. Here is a thread I started, this will answer most of your Q's. As for the PCM and harness use "EFI Guy" on here and not the person I had posted in my thread.http://classicbroncos.com/forums/showthread.php?t=218364

Also check out Scotts thread on this, he also has a good writeup on the swap, I don't recall the thread name but look up explorer swap

 

[garberz]

.....I currently have a set of Hookers on the 302. Are you saying to run the factory Explorer manifolds? Not sure if they are coming with the donor, but I'll check that out. Any issue with fitment in an EB with the Explorer manifolds?

I have the BC throttle cable now so that shouldn't be an issue. For PS, I have Hydroboost/4X4X2/Saginaw. I might be able to source an adapter for the current Saginaw HP fitting on my HP hose to the Explorer PS pump. For fuel pump, I planned on doing a frame rail mounted inline pump and an adjustable pressure regulator. I'm only running a rear tank, so I think that should work.

The factory Explorer manifolds fit just fine when running an automatic trans. I could see where there would an issue on the drivers side interfering with clutch linkage, but with the 4r70w, no problem. I'm running a C4, the manifolds are already installed on my current 302, 2 1/4" header pipes, single Spintech muffler, single 2 1/2" tail pipe.

As far as I know, Lee's is the only source for the adapter, AN/late model Ford P/S pumps. WH's might be stocking them now, but they're getting them from Lee's.

The fuel system is of a lot higher pressure than the earlier Mustang type. It's 62 psi, that's why the motor uses 17lb. injectors. A few that are running that system used the Explorer pump in the tank. EFI guy had info on the route you want to go. A good question for him.

Mark

 

[JK]

Just run the factory manifolds, they fit perfect.
Radiator- I just used a factory AL replacement from "Radiators for Less" on ebay, never had any cooling probs and have been running it all summer here in the SE heat and humidity. Here is a thread I started, this will answer most of your Q's. As for the PCM and harness use "EFI Guy" on here and not the person I had posted in my thread.http://classicbroncos.com/forums/showthread.php?t=218364

Also check out Scotts thread on this, he also has a good writeup on the swap, I don't recall the thread name but look up explorer swap

Did you run a reverse inlet/outlet? Or just a factory EB replacement with a crossover setup?

 

[rjrobin2002]

I ran a 92 2 core aluminum 4.0 Explorer radiator with the 92 shroud with my explorer 5.0. You can go get one with the shroud from a junk yard for 15 bucks and test fit it, if you dont like it your only out 15 bucks. I built a lower bracket and used the rubber donuts from the 92 explorer and bolted the top of the radiator to the fire wall. i will post some pictures later

 

[surfer-b]

Did you run a reverse inlet/outlet? Or just a factory EB replacement with a crossover setup?

Factory replacement

 

[KyleQ]

Ranger/Explorer radiator!
It fits, has trans coolers and cools awesome. Best part - $100 at the auto store with a lifetime warranty, was IN STOCK for me!

Cut the factory bullshit off the header panel and all you need are two holes to mount it off of. I've got nothing holding the bottom besides the lower hose and have not run into an issue - a simple fix would be some angle iron with holes and rubber grommets off the truck to hold it like factory. Hasn't been an issue for years on an abused trail truck.

Bronco original upper cut and flipped with exhaust pipe. Powerstroke lower cut and turned with exhaust pipe.

No cross over BS and it fits!

With trans cooler-

Without trans cooler-

 

[rjrobin2002]

Ranger/Explorer radiator!
It fits, has trans coolers and cools awesome. Best part - $100 at the auto store with a lifetime warranty, was IN STOCK for me!

Cut the factory bullshit off the header panel and all you need are two holes to mount it off of. I've got nothing holding the bottom besides the lower hose and have not run into an issue - a simple fix would be some angle iron with holes and rubber grommets off the truck to hold it like factory. Hasn't been an issue for years on an abused trail truck.

Bronco original upper cut and flipped with exhaust pipe. Powerstroke lower cut and turned with exhaust pipe.

No cross over BS and it fits!

With trans cooler-

Without trans cooler-

That is what I did, but I welded 2 pieces or angle and put the factory 92 lower grommits in. I used factory v8 explorer upper and lower radiator hoses with no cutting required, just some shortening on each end.

Look at page 4 on my build.

http://classicbroncos.com/forums/showthread.php?t=193571&page=4

 

[JK]

So I'm gonna go ahead and go with the explorer 4.0 radiator. Additional question, anyone see an issue with using only the built in tranny cooler? I know alot of people use an aux cooler in line, or only the aux cooler. Logic would assert that if I'm using the explorer motor, and the explorer trans, the explorer radiator would support cooling by itself. I know that we're talking about a 5.0 with a 4.0 radiator, but why even buy a radiator with a tranny cooler if I have to buy another cooler anyway? Anyone running a 5.0/4R70W combo with just the radiator for cooling?

 

[Kyle.malone]

i was going to suggest a Griffen Aluminum Radiator. it cools my 331 great with the Cherokee electric fan. They can put the factory parts on them so you can run factory hardware and switch the inlet\outlet if you want them to. It only took them 2 days to build mine with the trans cooler on it. I am still running a cooler in front of the radiator along with still utilizing the radiator cooling as well.

 

[tatersalad]

I am using a 94 explorer rad with 92 taurus 2 speed fan and bmw dual thermo to operate both speeds on a 351W setup. The highest temp I have seen is 230 while pulling a hill on over a 100 degree day. It was all wrecking yard stuff to get it up and running. I would prefer an all aluminum setup like this http://www.cxracing.com/mm5/merchan..._Code=RAD-EXPLORER-9192-AT&Category_Code=RDFD this one has all aluminum side tanks with the driverside widened to hold more water