Help with overall build plan/ideas! '91 4.0 XLT

[jcook100]

Hello there. This is my 1991 4.0L XLT that I am hoping to fix up. As this is my first project car, I am trying to put a plan of sorts together. As I think through the various options and components, I get overwhelmed pretty quickly. I was recently told about the semi-popular 2.3 turbo engine swap from a Thunderbird and am considering that, but am unsure just how much work it will entail, if it is worth it, etc.

What advice do you have for me in terms of the options I have, putting a plan together, etc.? The best way I can describe what I am hoping for in a final product is "quick and clean." I don't want to do anything too extreme, but would love to make it quick if possible. Should I consider this 2.3 turbo swap? If I don't, what am I able to do with the current 4.0? I have some additional current issues - AC, something with the clutch/transmission, cracked windshield, and some dings - but wanted to try and construct "a bigger picture" of the build to work with. I am open to all thoughts and ideas. Thanks.

 

[RonD]

A turbo charged 4cyl engine has the benefits of better MPG and more power when needed
The stock 2.3l turbo'ed engines are few and far between now, but you can still build a 2.3l SOHC turbo engine, just gets more expensive
If you have a 4.0l OHV engine/trans now then you would need to change computer and engine harness to a 2.3l turbo setup and put in a new transmission

Have a look here: https://www.therangerstation.com/tech_library/index.shtml
Bookmark that page

Go to Engines and then look at 2.3l Turbo articles to see what involved


Only other engine size swap that would make sense, IMO, would be putting in a 302/5.0l V8
Also need a different transmission
But you can do carb and distributor V8 so just basic wiring needed
Or
Buy a 1996-2001 Explorer with V8 and do a fuel injected/distributorless swap with computer and wiring harness

 

[1986RangerXL]

Turbo 2.3 will be a bit more expensive and complicated, especially if you build it up from a 2.3 that did not have a turbo set up.

A 5.0 is usually easier to find and therefore less expensive.

I haven't done either of the swaps so I can't speak to which is easier to do.

For a street truck I think the 2.3 would be the better option. For offroad usually see 5.0 because of low end grunt and not needing to spool the turbo

 

[jcook100]

Thanks RonD and 1986RangerXL. What are my options in terms of getting the most out of the current 4.0L? Are there common upgrades/mods I should consider?

 

[RonD]

No, nothing really for the 4.0l OHV

Its a good reliable 160HP engine, with good torque, should be pretty "peppy" in a regular cab
You can use a 4.10 rear axle ratio to make a bit faster off the line

You can of course spend money on it but not alot of "bang for the buck" options, until you get to Super Charger, and thats "next level" stuff like turbo chargers