'91 Explorer 4.0L to 5.0L SWAP

[tjs4x4]

I am coming over here to ask if anyone has done an explorer 4.0 to 5.0 engine/tranny swap? I have been over to explorerforums.com and not getting too much help. Will an F150 5.0, 4x4 and FIVE SPEED manual transmission fit my 1991 Explorer 4x4, 5 speed transmission? If so, would I need any adapters for the transfer case? I know I will need motor mounts, wiring harnesses. I just need to know what tranny will fit, and how I can tell what tranny to use. Also, will I have to replace my drivetrain? I'm tryin to get all my questions in here lol.

 

[adsm08]

The 8.8 and dana 35 will stand up to the 302. The last of the 302 F-100s had 8.8s. The rest of the drive train is composed of things you want to replace already. Shafts might need modified.

For your application I'd go with the t-5. Good strong trans, I think it will fit, its not huge.

I think there are other guys here who have put 5.0s in 1st gen explorers, maybe one of them will chime in on this, but I know that the T-5 fits in most rangers pretty easy, I imagine it'd fit the explorer similarly well.

 

[tjs4x4]

I was being helped by a nice guy on here, Kevin and he says that a 94-95 mustang engine along with an F150 tranny and transfer case will work fine, and that I'd need some clutch stuff and flywheel and block plate. What about exhaust parts?

 

[adsm08]

Not 100% sure, but I bet a set of manifolds from a 5.0 ex would work. Same for the rest of the exhaust.

 

[tjs4x4]

Ok. Looks like I'll still be piecing my Ex together lol.

 

[tjs4x4]

I'm starting to wonder if doing this is even worth my time and money. A couple good car buddies of mine say its not worth the hassle to do in such an old vehicle. I am partial to my X, but wonder if even rebuilding it with the 4.0 would be worth anything. I just am real unsure where to go from here. I think my tranny or transfer case is going out, got a bad ticking noise underneath and to the right side of my X by the TC and the Tranny. Cannot figure out what it is, and its getting worse. I'm torn between fixing up my ol' X and saving up for something better.....any thoughts guys/gals?

 

[adsm08]

Replace your bad u-joint, then get back to putting the 5.0 in it.

 

[Clem]

Putting a 5.0 into an Explorer is the same as putting one in any RBV.


Ray

 

[adsm08]

Replace your bad u-joint, then get back to putting the 5.0 in it.

Actually, scratch that. I'm a bit out of it tonight and didn't realize that whatever is making your noise it going to get replaced anyway.

If its the trans, you are replacing that. If its the t-case, you are replacing that, if its a U-joint, you might need to replace the whole d-shaft, but I'd at least get new u-joints anyway, you can't put all that power to old joints.