Here's Dan WHeeler's writeup. TOns of great info.
http://classicbroncos.com/forums/showthread.php?t=150669
I have a 98 explorer 5.0 w np435. I used a Luk clutch for 73 bronco and 90s f150 flywheel. Don't remember the part number but have it somewhere. It was cheap - like $50 at local parts store. I use a TBP mini starter.
I purchased the wildhorses Saginaw ps pump bracket. Had to do some minor trimming on it but it works great. Now that I have it, it would be super easy to make one.
http://www.wildhorses4x4.com/produc...-Bracket-Set-non-AC-only/EXPLORER5ENGINEPARTS.
I run an astro hydroboost. Had a local shop build the lines. They let me take the hose and fittings home to mock em up then they cut and crimped. My ps pump is from an early 90s suburban w hydroboost that has dual return in the reservoir. I have a 5.75" pulley on the ps pump that doesn't flow enough at idle to turn my tires very well. Once the RPM's get over about 1k it turns everything fine - even when locker is engaged in front in the rocks. I will soon be swapping in a 5" pulley that I have lying around. There's a lot of information on the net about ps rpm vs crank rpm, cavitation, pump size, etc. I have a lot of return line and stock ps cooler. Eventually, I will get a larger cooler and mount it in front of radiator.
I run factory 2bbl manifold and autolite 2bbl carb.
I use a 1985 mustang gt dizzy. Has proper gear for roller cam and was designed for carb. Just bought one from local parts store. One minor issue I had was with the vacuum advance. For whatever reason my ported vacuum was not pulling enough vac to properly advance the vac advance on the 85 dizzy. I switched to full manifold vac and set the timing accordingly and all is well. For some reason my ported vac pulls just a tad less than the other ports and that was enough to make a difference. Some day I may get a different springs in the dizzy but it works great for now. Idles smooth, good power and acceleration, etc.
I'm running a ford duraspark ignition mounted on driver side firewall.
Carter electric fuel pump without external pressure regulator, mounted on inside of driver side frame rail, above rear axle. So far I haven't had any fuel pressure issues. The pump is noisy at startup but quiets down after a bit. Use the rubber isolators on the mounts.
I'm using an oil pressure sensor switch to control the power to the fuelpump in case of roll over. I figured that was better than inertia switch for lots of offroad bouncing around. I run a 'T' into the stock oil pressure port on the side of the block. One port goes to the pressure switch and one goes to the gauge.
I eliminated the oil cooler adapter stuff and bought a simple little adapter to run a stock 302 oil filter. Threads into the block and allows the 302 filter to mount.
I kept the explorer stock 98 exhaust manifolds. They apparently flow better than the earlier manifolds but I'm sure they don't flow as good as a good set of headers. But being P-heads I didn't want to spring for the more expensive headers. The 98 explorer manifolds interfere with the clutch bell crank so I modified the bellcrank to fit around it.
Probably easier to just do a hydraulic clutch setup but I'm cheap and the mod was free. I modified the rest of the explorer two into 1 exhaust to fit under the bronco.
You have to run a different length serp belt with the Saginaw pump. Just run a rope around everything and measure to get length needed and take that to any parts house.
I run explorer metal blade clutch fan with modified earlier explorer 4.0 fan shroud.
Ford motorsports plug wires best bang for your buck.
4G alternator wiring allows elimination of the external voltage regulator and is pretty simple to wire.
FYI... when the time comes I too want to do EFI but I will be doing the explorer OBDII. Thanks to EFI guy - he has significantly simplified the process!
In the meantime I have yet to find an angle my 2bbl won't run and I've been straight up and down and almost on each side a few times. Leaves a lot of power on the table and is nowhere as efficient as EFI but it works great in the interim.
I have a champion radiator and can get you radiator hose numbers if you like. Upper I ended up splicing two different hoses together. Lower I found one that fits perfect. I use the explorer standard water pump.
Dan's thread has lots of great info, but holler if you think I can help.
