The PATS turned out to be a minor problem. The Explorer has a standalone PATS control module which was incorporated into the 2001+ Ranger PCM. So, going backwards in time to the 98~2001 Explorer PCM design, the control module needs to be added and wired. Plus it takes different style PATS keys and transceiver module. The PATS module and the PCM need to be introduced to each other using a dealer tool and also taught to recognize the new keys.

 

Looking good Bob! Iare you ready / done with the PATS re-synch? I may be able to get ahold of an NGS to do this if you want, let me know. I will ask my buddy tomorrow. Not sure if he has an Explorer card, but who knows.

Also, did D.S. quote what an all new shaft would have been? With the ability to use a stock front shaft and the low cost of the rear, I may just put in my 4406 when I pop the old 302 back in. Yes, I am temporarily throwing in the towel on the 351W and poping the 302 back in with a set of TW heads, cam, and a bypass for the Kenne Bell.

Sadly, I won't get to use these:





AND, I will only be running the FRPP explorer headers, which are only marginally better than the stockers. You made a wise choice with the TM headers. I have over $1000 in my custom headers, which A) are not optimal by a long shot, B) are only 1 3/4", and C) were done by me - I could not image the price if I would have had done. The engine bay on these trucks is down right rediculous. I guess that is what happens when you shoe horn a V8 into a platform that was never intended / designed for it!

 

Access to an NGS would be great but I'm not at that point yet.

I just dropped the engine in tonight with the new headers on it. Got the flex plate lined up with the torque converter and then it started to get late, so I put it away for the night.

Still waiting for the last of the PATS parts to arrive plus I have to modify the stock Ex cats to fit and build the rest of the system after the cats.

The interior's still all out, partly because of the swap, partly because of the Edge floor swap and partly because of the center console/ t-case shifter fantasy.

So it will still be awhile before I need the NGS. Thanks for the offer!

 

I have heard many people say that they have tried other shorties such as Mustang or even the V8 conversion headers sold for 97-back Rangers. Apparently, nothing comes close to fitting a 98+ Ranger engine bay that has the stock a-arm suspension and all of the original under hood stuff.

AFAIK, there are just 4 bolt-on possibilities for a 98+ 5.0L Ranger:

Early 5.0 Ex production stainless manifolds (poor flow);
Late 5.0 Ex production cast iron manifolds (poor flow);
FRPP stainless tube headers (similar layout to production but with improved flow);
Torque Monster headers (best available but still compromised).

 

looks real good Bob........i bet you wont even be able to tell something was done after the swap.....the way you make things look stock...

 

looking good, must be lots of fun.

 

Here's what the headers look like bolted up to the engine.

The unusual shape of the DS header is to clear the angled steering shaft.




The spaghetti on the passenger side is to clear the A/C box and upper A-arm and still have the outlet flange in the factory location. The fitting on the upper tube is for EGR.




Happiness is dropping in the V8 with its new tubes.

 

nice!!!!

 

i might have missed it, but did you do any performance mods to the 302 before dropping her in?

 

The engine itself is dead stock which is not too bad. It has the GT40 upper and lower intake similar to a 5.0 Cobra Mustang and the GT40P heads which are not bad for stock parts. A 65mm throttle body is also stock on 5.0L Explorers. It is a shame that these good flowing parts had to be strangled by the production Explorer exhaust manifolds. The headers should help a bunch.

I have a phenolic Ford Racing heat insulator that will go between the upper and lower manifolds and hopefully improve intake charge density a bit.

The only other mods are external to the engine itself and they are just minor breathing improvements. I'm using the stock 5.0L Ex duals and cats reshaped to fit bewteen the larger transfer case and the narrower Ranger frame rails. Then into a Magnaflow DI/DO and out into dual tailpipes. I'm going to reuse the SLP Thunderbolt air box and filter, too.

That's it.

 

So how long until done Bob? It looks like you have come along way already!

 

There's still a lot of little stuff to do but it all adds up. The biggest project left is the exhaust. Maybe 2 or 3 weeks.

 

Awesome, I am so excited for you! You already had a very unique Ranger, but now with all thats been done, I am sure its one of a kind. (especially for the year)

 

my dad has everything at his work, pipe bender etc.

 

sweet Bob......sounds like it is going to be a nice little ride.......

 

Lookin good bob! I think that is the first partial shot of the truck we have seen.

Side note... Bob needs a new camera

hehe

 

maybe if he gets that old (but still good) 4.0 and drivetrain sold, then he can buy one

 

too bad hes in michigan. I need a new tranny and everywhere i look wants over $1500 to replace or repair. Whats the point in that when I can just buy someones 4.0 and tranny laying around?

 

shipping wouldn't be but a couple hundred.....slap that dude on a pallet and off she goes...

 

The NGS is the scan tool the dealers use to read codes, troubleshoot problems and do simple mods like flash a canned program on the PCM, re-set PATS, adjust speedometer for tire size or gearing, etc.. It does not have functionallity like a SCT PRP to go in and change all the engine / trans parameters individually.

As for headers, Bob is 100% correct. Those are the only off the shelf parts to fit the Explorer 302 / 98+ rangers. That is why I went custom and even then you can see the compromises.

Bob, what is the plan for exhaust? If doing full custom and doing your self, Stahl headers and Stainlessworks (.net) are great places to get bends. Burns Stainless ($$$), Specialty Products Design (SPD-$$$), Chassis Shop (NW Michigan), Headers by ed, and Woolf aircraft (Romulus) are good places as well.

 

Maybe I missed this, but are you using a column shifter or a floor shifter for the automatic trans? What is your eventual plan for the interior?

 

he is using a column shifter.....i think there is a picture of it on page 3 of this thread.......if i remember, it is an Explorer column...

 

It is 98 Explorer shifter and park lock installed on the original 03 Ranger manual column. The shifter parts were left over from the Ex column I bought to do my steering wheel controls way back when.



The interior stays basic LII but gets the full length Ex console and trip computer. The original LII T/C shifter gets an F150 linkage and shifter boot.