Switch to a SOHC.
Getting more air into the chambers is the trick. Pretty limited choices on what to do. Headers and a good exhaust might help. There may be some advantage to getting rid of the flat pipe going over the radiator and getting a nicer looking air passage into the throttle body.
Having had a SOHC engine apart, it shows what needs to be done to get that 210hp out of a 160hp motor. The air passages are a straight shot into the chambers with a nice, big, round port. The lack of pushrods allow that, and the lack of pushrods and lack of heavy valve lifters also allows the motor a lot more rpm capability--it's hard to control a heavy valvetrain at higher revs.
The weight of the valvetrain isn't the only relevant factor to the power band and the inability of the 4.0OHV to rev, the cam timing (lift and duration)
are, but they were chosen to complement the intended use of the
engine, to actually move a TRUCK.
And while those big ports on the 4.0SOHC engine are real "sexy" that wasn't all of the change.... you should study up on the "lightweight rotating assembly" that ford switched over to in mid '97 (yes, on the OHV engines)
Granted the engine wouldn't rev without those big ports, but it wouldn't rev with ONLY those big ports... it would try to fly apart because the 4.0OHV isn't dynamically stable above 4900rpm.
The 4.0OHV engine was actually engineered to work well within
a very specific requirements. it does EXACTLY what it was designed
to do.
the 4.0OHC was designed for a different set of requirements
and it really isn't nearly as good a "truck" engine.
Of course if you are driving a truck as a "Fashion statement" rather than actually using it to tow or haul stuff you probably want the SOHC engine...
Frankly if I really wanted 215-ish hp instead of the 175-ish I supposedly
get from my Borla header equipped 4.0 I wouldn't bother with a 4.0SOHC, I'd put in a 5.0
Frankly I suspect a carefully tuned 5.0 with 3.55 gears might actually get better highway mileage than my 4.0 has with 4.10's
At one point before I put a 4.0 in my truck I was actually toying
with putting in a roller cam 5.8 and 3.27 gears...
My brother was actually tickling 20mpg with an F250 4x4 5sp on 33's
with an EFI5.8, I figuire my Ranger with 3/4 the frontal area and
the better part of a ton lighter could do better...
AD