Fuel Issue - 99 Ranger 2.5 getting a 98 Explorer 5.0

[Rangstang]

Searched back to June of 2011 under V8 Conversion forum for "fuel" and didn't see anything matching my issue, so here goes...

I've got a 99 Ranger formerly 2.5L that I'm installing a 98 Explorer 5.0L complete with original injection, engine harness, PCM, and fuel system (return style). Since my Ranger is a return-less system and the tank is not yet visible to me, I'm guessing that there is only one port on top of the tank (supply line). I looked up some fuel pump/sending unit assemblies on Autozone's website, yet it shows the 99 Ranger assembly as having 2 ports, one looking like a return (1/4"). Is this pic incorrect or is this second port some sort of vapor return? If it's a vapor return, can I utilize it for a fuel return or do I need to install an additional port for the fuel return?

 

[Rangstang]

Okay, doing searches on the web for converting returnless systems, I found this Moroso kit that used by many Mustang guys. Is this what the Ranger V8 crowd is using too?

http://www.summitracing.com/parts/MOR-65385

 

[sacredauto]

That's pretty nifty. It looks like it ought to work well. It may be added to my parts list

 

[Mac]

Well I looked in the 2000 Ranger shop manual and they show three, supply, return and vent. Got to be out of date a couple of years. One thing I think you've over looked is how you are going to drop the pressure from the Ranger pump (56-72 psi) to the 35-45 that the Explorer motor is looking for. Some switch in an Explorer or Mustang pump that would have the right pressure and the correct number of fittings.
Dave of the Nord

 

[Rangstang]

Well I looked in the 2000 Ranger shop manual and they show three, supply, return and vent. Got to be out of date a couple of years. One thing I think you've over looked is how you are going to drop the pressure from the Ranger pump (56-72 psi) to the 35-45 that the Explorer motor is looking for. Some switch in an Explorer or Mustang pump that would have the right pressure and the correct number of fittings.
Dave of the Nord

Explorer fuel pump/sender assy only had 2 also. It's sitting in the bed of the truck during the swap. It has no internal regulator as it's on the fuel rail. I figured it would be alright since I'm running the Explorer return fuel rail which has a regulator built in which I figured would drop the pressure to the necessary psi. Would too great of pressure coming in cause a problem?

 

[Rangstang]

That's pretty nifty. It looks like it ought to work well. It may be added to my parts list

I made a custom coupler just like it because the fuel filler on a Ranger is 1.5" ID and the one on Summit's site is for 2" ID. Used a muffler coupler, drilled a hole, bent 1/4" steel tubing and welded in for a total of $3.

 

[Rangstang]

Here's a pic: