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Per the OP's questions:
Yes, the Returnless fuel rails will work with a 96-98 motor without a problem *I am running this setup*
Yes, You will have to use a 99-01 ECU *I'm using a 01 ECU*, HOWEVER I've found that several tuners are able to change this setting and/or remove PATS with a tune. *I'm using a crappy sniper, and it offers BOTH Of these options, to disable PATS on an ECU, or to change the Fuel system setting to returnless on an older ECU.
BE AWARE, You will need to have custom engine mount BRACKETS made, as the factory ones will not work on your engine mounts. Your engine MOUNTS will work assuming you have a 4.0 SOHC in the truck currently.
My truck is a 98 std cab, stepside bed, 2wd, and I'm running a 98 engine, with factory 4.0 SOHC Engine mounts, and custom engine BRACKETS, with returnless fuel rails, a 98 2wd Explorer transmission, a 2001 ECU with PATS disabled and the shifts firmed up, Had to wire up a 2001 CPS Sensor *Only real difference between the wiring of 96-2001*, a slipyolk off a 9...7? Crown Victoria *4R70W*, with my factory driveshaft *4cyl*.
I bought a donor truck for my swap, and ended up using very little of it because it was a 4WD.....
I STRONGLY recommend finding a 99 or newer 2wd if possible as you will be able to use far more of the truck, and swap in almost everything 'plug and play'
I don't know what rear-end you currently have in your 05, but I took the explorer rear end I had pulled, and ended up trading it + $50 for a 2005 Ranger FX4 Level 2 rear end so I didn't have to deal with changing the shock perches, and I was already going to lower it, so I had no point in getting an axle that already sat ontop. (On that note, if you want to use the explorers rear end, keep in mind it sits above the leafs opposed to below as the ranger has normally so it will drop the tail of the truck 2-3 inches)
Yes, the Returnless fuel rails will work with a 96-98 motor without a problem *I am running this setup*
Yes, You will have to use a 99-01 ECU *I'm using a 01 ECU*, HOWEVER I've found that several tuners are able to change this setting and/or remove PATS with a tune. *I'm using a crappy sniper, and it offers BOTH Of these options, to disable PATS on an ECU, or to change the Fuel system setting to returnless on an older ECU.
BE AWARE, You will need to have custom engine mount BRACKETS made, as the factory ones will not work on your engine mounts. Your engine MOUNTS will work assuming you have a 4.0 SOHC in the truck currently.
My truck is a 98 std cab, stepside bed, 2wd, and I'm running a 98 engine, with factory 4.0 SOHC Engine mounts, and custom engine BRACKETS, with returnless fuel rails, a 98 2wd Explorer transmission, a 2001 ECU with PATS disabled and the shifts firmed up, Had to wire up a 2001 CPS Sensor *Only real difference between the wiring of 96-2001*, a slipyolk off a 9...7? Crown Victoria *4R70W*, with my factory driveshaft *4cyl*.
I bought a donor truck for my swap, and ended up using very little of it because it was a 4WD.....
I STRONGLY recommend finding a 99 or newer 2wd if possible as you will be able to use far more of the truck, and swap in almost everything 'plug and play'
I don't know what rear-end you currently have in your 05, but I took the explorer rear end I had pulled, and ended up trading it + $50 for a 2005 Ranger FX4 Level 2 rear end so I didn't have to deal with changing the shock perches, and I was already going to lower it, so I had no point in getting an axle that already sat ontop. (On that note, if you want to use the explorers rear end, keep in mind it sits above the leafs opposed to below as the ranger has normally so it will drop the tail of the truck 2-3 inches)
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the earlier 3bar and boat motors though
