96 4.0L tt help and info needed

[RangerSVT]

Okay guru's, I have some knowledge, I'll start first by telling what I have and then what I want to do...
I have a 96 4.0L OHV, 5R55E and 1354E...I have two turbos from 88 T-bird TC's (not sure what size housings, I know they are the same, too lazy to go outside and look right now) they are the IHI turbo's, about 18psi max, a 3" inlet/3" outlet on opposite ends, 14"x30"x4" IC rated at 60psi @ 1000hp with less than 0.2 psi drop across the coils, narrow band AFR, stock ecu, injectors, maf, intake and airbox.
I want to twin turbo my truck, one on each bank (no compound or any of that, not interested, I'm sticking to what I know), I plan on moving my battery to the bed, and removing airbox, so each turbo behind each headlight area. both IC inlet pipes will enter on driverside, exit on passenger side and 90 into maf then TB. I know how to tune the engine to get max fuel out of stock setup (learned by accident modifying exhaust). I plan to drill/tap the top sides of the oil pan, above the oil level of course, and run a tee with 3/8 oil line feed to the twins.
Okay, questions, I believe the stock wastegate is set at 10 to 12psi, will my motor survive, or will I need to upgrade the injectors?? Will injectors from a 5.0L HO (mustang, lincoln, explorer 5.0L) work, or will I need to buy aftermarket?? Can I get away with running without a BOV for a few months?? I have a BOV from another turbo setup I have, its from a 91 talon AWD 2.0L, will that work/should I use that?? I thought about making custom headers, but for now I'll use the inverted stock manifold method. I'm not familiar with the Gen 1 4.0's, I hear they are prone to blown HG's, do I fall into that category?? If I do blow a HG, would using head studs with copper HG's work better?? Do I have to worry about the heads cracking as well, or is that just a Gen 1 prob?? I assume the Gen 1 4.0's were pre OBDII, am I right on that?? I'm sure I'll have more, but this is a start.

 

[turbo cat]

I would run some calculations on using those turbochargers. I have played around with turbocharging the 4.0 in a few ways (all low budget crap). The 4.0 bottom end is quite strong and can handle alot of boost. You have an EECV system so you can use Moates or SCT or Tweecer or Sniper to tune the setup. Or rig it with an FMU but tuning would be 10x better. the ford bosch style injectors are all the same (bolt ins) except the newer style GEN III injectors that have the rounded oval plugs and even those can be used with adapters. 30-42# injectors will most likely keep the fire fed and a larger pump would be nice. The 4.0 is a torque motor not a high reving race motor. I rather have a turbo that is sized for full boost by 2000 and dosent choke the motor too hard on the turbine side. The turbo i have used for a year on my 4.0 is on the small side but the response is quick. Full boost before 2000 my peak torque was at 2400 rpm 250rwtq on a dynojet thru a 4wd drivetrain. I see no reason to use custom headers as the stock manifolds can be flipped easy and so far they have proved themselves durable in a turbo application. Also cast iron holds in more heat=hot expanding high veocity gases=faster spool. To exactly match the ports there is some porting on the inlets of the manifolds. I did not do this as the lip was small (and time was against me) however take your time and ditch the lip as that is performance i most likely have lost due to flow and turbulance. The IHIs you have may work but I would use a turbo calculator to verify. I personally rather just have a correctly sized single setup for fast spool. ANyways do post pics up.

 

[CopyKat]

Here are some ideas I've found when researching for my turbo 4.0L project.

 

[RangerSVT]

BTW, I also have a combo vac/boost guage to 20psi, forgot to mention. Good points, I guess I should add my driving style as well. My truck is 4x4, so I'm not looking for top end power, low and mid range is my goal, I only stated using the IHI's cause I already have them, and I have only one turbo from the talon/eclipse (T03 I think), which is way smaller than what my motor needs. I plan on keeping the IHI's to tt the 5.0L thats going to replace my tired 4.0L...
Would I do better using just one IHI, or both?? What vehicle can I get the 30+ injectors from?? I guess I should also mention that this build will be less than low budget, if it happens. I'm short a starter, starter plate(plate between engine and trans) and V8 explorer tcase from doing my V8 swap. My 5.0's oil pan is already drilled for dual return lines (an-10 on each side), oil supply T, and headers...
So should I try this, or just wait for the V8 swap??
SVT

 

[turbo cat]

do you have any fabrication experience? Its alot of work but worth the effort. Mine was super low budget I spent 150$ on the materials for my kit minus tuning. All I have is a FMU for my setup that tacked on another 60$. I recomend getting the correct harware/software to tune it. If yout truck an auot or automatic? Also as i stated since your truck is a 4wd and the goal is torque be careful on the size of turbo you use or it will have major lag that will put the boost in a unuseable range. Right now i just have a single T3 and Im happy with the response. Im only running 5 lbs but it comes on instantly.

 

[turbo cat]

Heres some turbo 4.0 builds
http://therangerstation.com/forums/showthread.php?t=39990

heres my low low budget turbo hack job
http://therangerstation.com/forums/showthread.php?t=33113

and heres another good one with alot of money invested
http://explorerforum.com/forums/showthread.php?t=234088

 

[RangerSVT]

Yeah, I got fab experience and the tools to go with it, I got a tubing bender, MIG, chop saw, torches, sawzall, etc. Not sure on your ? is, if I got auto or automatic....I have the 5R55E, 5 speed automatic trans, 13" lift sittin on 35's...

Still don't know if the IHI will work, does anyone have any experience with the IHI, I know the turbo 2.3L guys use them left and right, but on a 4.0 the IHI compared to the Eclipse (T-03 I think), which one would be better?? If the trim size will help, I'll get those off the turbos if need be, but the question still remains, one IHI or 2?? IHI or T-03?? Thanks guys
SVT

 

[turbo cat]

sorry i meant auto or manual. As for the decison of which turbo(s) to pick. You may want to do some basis investigation adn use a turbo calculator. What size is the exhaust housing on the T3 from the eclipse? twin IHI turbos probally would spool up quick but i couldnt tell you when exactly they will spool as it comes down to gearing/ load/ tuning/ gas velocity/ compression......However you have an automatic so when your out on the road once they spool they will stay spooled until you lift your foot from the throttle. You dont really need a BOV in an low boost automatic setup but it can't hurt to install one soon enough down the road. And do go with strait thru mufflers as backpressure reduces response of a turbocahrger.

 

[skyy_4life]

yea it would be good to have a bov anyway for times when u release gas quickly, but i would just go with straight pipes and no muffler....

 

[turbo cat]

Are the turbos you have the IHI RHB52? I havent messed with them much but they have tiny turbione housings. two of them will probally spool up with the quickness on the 4.0. have you checked shaft play on the turbos? I also ran the compressor maps with the twin IHI turbops and the turbos were in the effeciency range. Right on the map.

 

[RangerSVT]

Okay, I finally went out to the garage and dug the 4 turbos out of their hiding spots...I'll start with the Eclipse/Talon turbo, I couldn't find the ID tags, no doubt they've been removed...On the cold housing is has stamped on it TD04HL, on the hot housing 050, I'm assuming this means 0.50 trim, on the cold side intake measures 2" OD with 1/4" lip(figure 1.5"), exhaust 1.5" ID. On the hot side 2" exhaust, 1.75" intake...
I got two complete IHI's, and one in pieces, needs a mainshaft, the main housing is stamped with R37K. The two complete IHI's have R17G on one and R17E on the other. Stamping on the hot housings are as follows:
3
52
20-R
0
On the other turbo housing
4
52
20-R
0
Both intakes are stamped with an 86, so I'm assuming these boys are .52/.86 trims...Both IHI's have the same measurements, they are cold side 2 1/8" OD intake, 2" OD exhaust, hot side is 1.75" x 2.25" (oval port) ID, 1 7/8" exhaust ID...sorry it took so long to get these measurements and specs up, but here they are...I am also currently running a singe 3" exhaust to a 2 chamber flowmaster, turning out in front of the rear tire with a 7", 24" long desiel tip...look carefully and you can see half of my exhaust, and I plan on running the same setup

SVT

 

[turbo cat]

If it were me I would use the IHI turbos (check there play to see if they need to be rebuilt first) and ditch the flowmaster mufflers as they are a baffled muffler and will rob performance in a turbocharged application. You need muffler(s) that you can see strait thru.

 

[RangerSVT]

I've been through the turbos, they're good to go. I need to get a couple of lines made for oil supply and return, as well as intake piping, then I'll start the install...Thanks
SVT

 

[RangerSVT]

I'm not running the cats, so I have very little backpressure as it is...Would injectors from a V8 explorer, mustang, or lincoln Mark VII, VIII, or continental work?? If not, which vehicle should I grab them from??
SVT

 

[turbo cat]

yes the injectors will work. The 89-93 thunderbird SCs have 30lb injectors adn the 94-95 tbird sc is 38lb injectors i think. mark 8s with the 32v 4.6 have 24lbers and standard mustnag gts have tthe same 19lbers as you have in your truck right now. As far a backpressure it has alot more to do with velocity. a flowmaster kills velocity due to the decompression of gases and the baffler that creates a obsticale. this reduces exhaust gas velocity causeing pulses that will flow back towards the turbine and this can slow the turbine speed. sometimes reducing response and robbing power. Its a generall known fact that not going with a strait thru muffler will be leaving free performance on the table. Or go mufflerless as the turbines will act as mufflers and it will be probally as loud as it is now with just a flowmaster.