I've been all over this forum and countless others, and I'm ready to get going on this swap since my 4cyl 2WD is dying. I've got two choices 01 or 97 Ex 302. Not sure which route to go, whether wiring the PATS and Speedo in the 01 or the fuel system and non PATS in the 97 is easier, any advice would be appreciated before I rip my truck apart.


Also. does anyone know if Torque Monster is still around?

 

PATS can be bypassed with custom tuning, so as long as you don't mind paying a little extra for that, it's nothing to worry about.

Last I heard, you can still buy Torque Monster headers from Al's out in CA. Expect to wait a few months to get them, but they're definitely worth it!

 

Don't forget the '97 has a speed signal solution, the later does not.

I used a '96 Expo 5.0 in my 02 Ranger and can say moding the fuel system was not a big deal. Wiring in the PATS would likely be easier and if I remember correctly, the 4 Cyl Rangers use the GEM for the speed signal removing the one "gotcha" in the later Expo swaps.

If you don't have the keys to the doner Expo, the '97 would probably be the better option unless a custom tune was planned for anyway.

Either doner would work, both have solutions and challenges the other lacks. Pick your poison!

 

Yeah, the 97 is what I'm leaning towards, it seems easier overall as far as electrical issues starting the truck. was there a ton of modification to get the engine harness to plug into the ranger Cab harness? or wiring the non PATS into the PATS ignition?

 

Non pats '97 is a non-issue for the 2.3 I think, no PATS on the 4 cyls

Only a handfull of wiring changes, the difficult to sort out is the a/c circuit. The logic for the a/c is very different between the Ranger and Explorer so getting the two to play nice can be tricky.

In the Rangers, the a/c control panel simply tells the PCM if you've selected A/C or not -- the PCM has 100% control over the compressor.

In the Explorer, the PCM is simply an on/off switch along with the high and low pressure switches, the a/c control panel is in control.

 

Some highlights from my '96/'02 build.

http://www.therangerstation.com/forums/showthread.php?t=158427

Best of my knowledge, Torque Monster headers are not currently available. Al's Headers could/would not keep up with demand. On the upside, Robert the designer is hoping to find another solution for getting them made.

OBX did a run of TM clones but those very quickly sold out and no signs of 2nd run.

So, no, at the moment there is no good header solution.

The original Ford performance, TM's and OBX's all show up used on flea.bay and on Ranger or Explorer forums from time to time.

 

Thanks for the help, this project might have to go on hold until I can find headers though.

 

Does anyone know if I can just use stock manifolds even though there not the best performance wise? Just to bide time until I can find a set of TMs or OBX.

 

Yes, the Expo manifolds work. The later cast flow better than the crack prone tubular ones.

1st gen Mustang 298 manifolds are reputed to clear the conflict points, but won't work with the original Expo cats.

 

Could you tell me how to bypass the PATS system. Thank you.

 

just wondering how your swap is going. I used 302 factory exhaust as it came out of donor. from manifolds to daul cats, I am thinking about getting shorty headers but not right now.