Explorer Serpentine - Griffin, PSC, BC, and WH - Making everyone play nice

[72_EB]

I've been meaning to get a few pictures up and post a couple parts numbers folks might find useful if they end up going with the Explorer serpentine, WH's High Volume PSC pump, and a Griffin or other radiator with swapped inlet/outlets. I found a quite few threads on the stuff a lot of folks have already dealt with (upper radiator hose, lower idler pulley - posted again below), but I didn't find a ton of info on the PSC pump on here. KyleQ is running this pump, but he's full hydro and I am going to run the stock power steering box, so the setup was obviously a bit little different. Luckily, the boys at my local Advance Auto Parts were very cool about looking up hose #s or letting me rifle through their hose section so I could stuff that fit and had good clearance. They are all gearheads themselves and had a good time with them last night at local car show talking about their cars and also my Bronco projects.
Anyway, below are some pictures and descriptions that hopefully will help others if they decided to go with the WH PSC pump. I'll post more info when I get my box rebuild and have it finally up and running.

 

[72_EB]

Here's the first issue, which I believe is also mentioned by Daddy4Zack on WH's page in the review of the pump - Spacers.
*Definitely glue your spacers on the Explorer bracket prior to mounting and bolting up the pump.* There is no way you will be getting the pump bolted on unless your spacers are attached ahead of time (especially that lower spacer). My pump needed 1/4" of spacing between pump and the bracket to get the belt and pulley depth right and the same as the factory pump and pulley spacing.
I used a combination of 1/8" and 1/4" chrome spacers (found at local Menard's).

 

[72_EB]

Here's a shot of the belt routing (without shroud on) so you can also see how I ran my pressure hose and the notching required in the factory Explorer bracket for running the hose.
Running the pressure hose out the bottom caused a number of issues with clearance for me with the clutch fan, lower radiator hose, and my BC braided lines. Using the factory Early Bronco lower radiator hose got all these items closer than I liked. I had to make a clip for the fuel pressure and return lines to the water pump and I found a good lower hose that kept my pressure hose away from both the fan and the lower hose. Part # is Dayco 72048. Out a '90s Dodge trucks I believe. I had to cut about a 1/4" off the end of the hose, but it fit great. Photo looks like the hose is on top of the radiator hose, but there is easily a good inch of clearance. Same with the fan.
The serpentine belt I used was a Dayco 5060835 (83.5").

 

[72_EB]

Here's another shot of the belt and a shot of the smaller idler pulley
(Napa #36079 - 60mm) that BroncoBernie discovered. Cleared the frame great with Napa motor mounts.

 

[72_EB]

Here's the upper hose I used with the reverse radiator fittings. Dayco #71654. Trailpsycho found this one for his rig. It does touch the top of the alternator, but I don't think this will cause any long term overheating issues or anything with the alternator. Trailpsycho might chime in. He's been running it a while now I believe. There are no moving parts here to worry about. I did grab a cover at the boneyard since my hose didn't come with one. Should work good.

 

[72_EB]

Other things of note -

I had to install my pressure hose before installing pump and bracket onto the engine. If it ever has to come off again for service, pressure hose will need to be removed from box and then whole bracket, pump, and assembly removed as one unit with hose attached.

My pressure hose I had made up at Aeroquip in Chicago was 6AN female at the pump end and 6AN to 11/16" inverted flare on box side (Aeroquip #2965).

I took the washer off the lower bracket bolt to get the pressure hose a little more tucked up next to it.

Hopefully, these items help folks out. I swear I had that damn Explorer bracket off like 20 times getting stuff to fit the way I wanted! Finally satisfied with everything and this pump should hopefully last for years with 35s.

 

[Tonka7777]

Great thread. Thanks for putting this together.

 

[toddz69]

Great write-up and excellent research on your part. It certainly can be time-consuming! You have a real clean install.

Todd Z.

 

[stretch]

Fantastic write up. You need to post this in the Tech pages. I'm sure this will help more than one person.

 

[BucknEB]

Thanks for posting. I'll be doing this swap real soon.

 

[KyleQ]

Here is my factory upper hose with an Explorer radiator modified to fit-



Any my full hydro setup really isn't any different then any other setup - I've got the same high and low pressure lines and they go to the same exact place as the factory box, they are just nice DIY hoses with -6 ends. Then I have two high pressure lines that go to the cylinder, just like any hydro assist setup. It's not vodoo

 

[72_EB]

No, no voodoo, but found it required a little more monkeying with than most of Jim's products at Wild Horses. The instructions left a little to be desired and I only had the black and white bracket photos until I saw your larger color shots.
I did want to address the pressure hose routing as it might be something to Jim decides to change or modify in the future. With the items I used, it should be fairly straightforward for anyone using a stock Ford power steering box whether stock, F100, or Rockcrawler.