Hey guys,

Well I got my kit and have went over the installation. I don't have it on yet because of some MAJOR differences.

1st The lower intakes. Yes, we all thought they are the same but they aren't. The late model, 02up I'm guessing maybe 01's, have smaller bolts. 6mm to be excat. They also only have 4 bolts securing the upper intake to the lower where as the previous year models have 6.

2nd The IAT. The 02up Fords have them intigrated into the Mass air meter, its a 6 pin connector. The early styles have a 4 pin mass air and the IAT is in the air tube.

3rd Manifold heater hoses or the hot water bypass will have to be done. The late models don't have this function, the small tubes run around the PCV valve instead of into the back of the TB.

4th EGR valve, forget about it. No way to hook it up no place to. Sorry you CARB and emissions guys, I wish I could tell you different.

These are just some of the things I've ran into with my install on my 99'. I will still have it on and running soon so I should have answers to each of these questions on here too.

Now you know why it's so hard to design a kit for so many years, the small things that change are the things that hurt.

Later Doug904.

On a side note, can anyone with an 00-01 look at their engine and tell me if they have an EGR? If so do you have a plastic or aluminum upper intake? Thanks!!

Yes Doug, My 2000 3.0 is EGR equipped, the intake is cast aluminum. Don't know if this helps ya but there ya have it.

Andy

damnit, sad but thats really all i have to say :bawl:

Please don't dismay, I have passed my findings on to Whipple along with another company in the aftermarket. With both of there help we will bolt this kit to previous year models. Now unfortunatly it won't be emissions legal but its the price you pay for real performance I guess?

Later Doug904.

emissions who cares about those i just want a supercharger.:nuts:

well i hope it all works out and i dont have emissions tests...yet

Hey Doug I dont mean to be a pain in your ass but can you look at a say 01 mazda to see if there's a difference in that and the ranger???

Tennessee does emissions testing...and they're asses about it.

This is really bad news. Looks like I won't be able to go this route. This truck is my daily driver and I can't afford to pay gratuities to the DOT for the privalege of driving my truck. I already pay Ford. :(

Is there abslutely no way to stay legal with this kit? Are you talking about OBD II compliance or the sniffer test? We have to get tested to renew our tags every year.

Would we simply be able to buy an '02 lower intake and EGR plumbing and make it work on our '00 models?

If not, I guess I'm going the route Trailhead 00 just took. I was really impressed with his setup with the 5.0.

Keep me informed, Doug. I was really looking forward to helping you out ($$$) and meeting you so we could tune this beast :).

Well the thing is that the 02's and up don't have an EGR valve at all. That's why the kit doesn't have any provisions for it. Do they do a visual inpection checking for certain emission items or do they just do a sniffer test? Its possible that the truck could pass an emissions test. After I get mine installed if thats the case I don't mind bringing it up and maybe having it tested just for kicks to see if it would pass.

later Doug904

my dad races a 92 t bird 302 stroked to 347 525 hp . factory it had an air pump and egr valve . i inspected it at my shop and it went right through no air pump and no egr . at our state inspection they dont even open the hood! but i do my own inspection so i could care less if its emmisions legal . BRING IT ON !!!:hug:

If the install time is as low as advertised (I heard 90 minutes), it shouldn't be too bad to remove it, get tested and inspected, and slap it on the following day or week. And for the week that it is off, it will really make you appreciate it when it is on.

:E Good point, Tate. I'm not quite that mechanically inclined, yet.

Damn John, don`t you have a relative that lives outside Rutherford county , or one that lives in a county that doesn`t touch Davidson county ? You could always register your truck there, they`d never know the differance.

Coffee and Franklin don`t have emissions testing yet since we don`t touch Davidson county.

That way you could still do the SC and not have to pay Rutherford county`s stupid wheel tax :)

I had thought about that, but was unsure as to what would happen if I got pulled over. Because you know I won't be driving 55. ;)

Id just take it off for an inspection, and then put it back on. Seriously now, the first 2 times might be kinda tough, but after some practice youll fall into a routine and wont have any more trouble.

Hey doug if you get it to work on the pre 02's can you explain how you overcame those differences?

You shouldn`t have any problem. My aunt has been doing it that way ever since Rutherford county started their wheel tax. As long as the vehicle is registered to the address you put down, I don`t see what they could say.

I've got an 01. My upper intake is held by 6 6mm bolts...not 4 6's or 6 8's. Are you sure there aren't still 6? I have 4 in the center in a square pattern, and one on the front and back of the manifold that are shorter and kind of hidden. I also have an EGR. My IAT is on my MAF and not on the airtube though. Seems like the some of the changes you mention happened in 01 and others in 02. Since the EGR just a valve that allows some exhaust into the intake, do you think you could remotely mount it to a bracket somewhere close and run a tube to a fitting in the intake somewhere before the sc? If not, I'm not real concerned about emissions here in FL. I doubt they changed the block or heads, so I bet its possible to switch to a 02-04 lower intake. Might as well port it out before putting it in. If its illegal not to have an EGR on 01, how is it legal on an 02 not to have one? Whatever the 02 has to bypass that, is it swappable to the 01? I can't wait to see how this works out. I'm sure its possible....its the same base engine...just what is necessary we will see.

~Russell

Does anyone know how much the kit costs? also I bet it will take longer to install than they say, but that is just my opinion.

Doug if you need any help let us know we're all after the same thing some people are alot closer than me but if it takes it I'll be there any weekend you ask.
ask a week in advance or you will have to put up with my girl fussing at you cause when she yells at me I'll give her your add.

I'm sure you can remove the EGR and with the right computer tuning it'd still pass emissions and not through a CEL. The problem is, it is illegal to remove emissions equipment from your vehicle. So while it can be made it work, it wouldn't be carb legal anymore and they'd have to sell the kit for offroad use only.

And with removing it for inspection, since the computer needs to be reflashed it might not be possible. Of course the 01 and earlier guys are probably going to have to use a chip, in which case you could just remove the chip when you went for inspection.

Well, got some more done and ran into some more differences.

The injectors sent with the kit aren't going to work even with the 98-00' styles. Not a big deal though as I'm familiar with this difference in doing the split port mustang swaps. You have to cut and solder new style connectors on the ends. I'll get some from a harness Monday.

Next, the coil packs and mounting. The location on the 02's are mounted on the valve covers, well the location on the 99 is a brace from the exhaust to the upper intake. I haven't quite figured out what I plan on doing here but there again this is no real setback.


Where this kit will not pass a visual inspection it may pass a sniff test. Any good running vehicle with a half way decent cat and taken care of engine should pass.

later Doug904.

Wouldn't it be easier to just use a larger injector that is compatible with the plugs that are on the truck now, rather than adapt the plugs to fit the injectors that come with the kit? Just trying to think about this from the simplest perspective. Just seems that not everyone is going to want to cut up their wiring harness, plus I would think it would make it easier for removal later on if they wanted to sell the kit or the truck.

Originally posted by Wed Turner
Wouldn't it be easier to just use a larger injector that is compatible with the plugs that are on the truck now, rather than adapt the plugs to fit the injectors that come with the kit? Just trying to think about this from the simplest perspective. Just seems that not everyone is going to want to cut up their wiring harness, plus I would think it would make it easier for removal later on if they wanted to sell the kit or the truck.


Yes, it would especially with a aftermarket kit, but with the kit straight from Whipple I'm trying to use their Mass air meter and the injectors. If I was designing the kit for resale for someone else I would completely use a different injector and mass air meter.

Later Doug904.

Damn, this is turning into a bigger deal than what you thought, isn`t it Doug ? The more I hear, the less enthuzied(sp?) I get about the kit. The way it sounds, they`ve made the kit so year specific, its not going to be an easy swap. Most of us don`t have the access you have to the parts that are needed, so instead of this being a $3K installed, its gonna run even upwards of that.

Damn! this is making me less enthused (sp?) about the SC

Doug:
I appreciate you letting us know how things are going.
Thanks for your time!
Jim

we appreciate you info and while it's difficult to be patient will do our best. keep up your good work.

Well, please remember I have a specific kit designed for the 02-04 models. I'm working with Whipple as well to help either redesign the kit a bit to make it more flexable as in years it will fit or with another company that will make it for the earlier years specific. Someone has to do the research for it to work, I'm honored they chose me. I assure you it will be on my truck and I will be able to either tell you what to do or be able to tell a company how to mod their kits in order for it to work.

later Doug904.

If you8 have a flex fuel truck you allready have injectors close to the 24lb ones they send you. I have a set of flex fuel ones flowed and matched at 25.8 and a set of 42lb ones too. how does the 02 and up deal with the egr. many questines anyone have answers.
FELGAR_1

The 02's and newer don't have and EGR.

I've asked before, but I'll ask again. If 01's have to have an EGR, why is it legal for 02s not to have one? Its just a valve allowing exhaust to come into the cylinder when max power is not called for. With a supercharger I would think you'd always want as much air as possible, and the little exhaust that would come in wouldnt really affect anything.

~Russell

It doesn't need egr to meet emisions It does hurt hp because there is less oxygen and hotter air but in proper tuning it can give you more tourqe by slowing the rate the fuel is burned.

doug
if the older 3.0 have six blots holding the upper intake on and the 02 and newer have 4 how did you ge that fixed
for non boosted 3.0 can that still bolt up and work like it should just with out the two bolts. you see i am doin the upper swap and if this is true i may have more work cut out fo me than i thought. but never the less the only two that i see that will not be there will be the inter bolts that in my case they also hold the coil pack on top of the intake runner, with seprate nuts on the bolts
i have a 94 3.0

I ask doeg the same thing he said he would just drill them out and not worry about the two in the center the both use the same gasket.

i see ok no problem

the '02 and up have the egr built into the cam from what I have read so that is why the 02 and newer don't have an egr valve or plumbing

got your pm 3.0 kaos
thanks again

the '02 and up have the egr built into the cam from what I have read so that is why the 02 and newer don't have an egr valve or plumbing


Finally, an answer...thanks. How would that work, though? The egr kicks on whenever the engine isnt at full throttle, but its independent of RPM so having valve overlap or something wouldnt really do the same thing. Maybe I'm thinking of it wrong.....oh well, thats not what this thread is about, sorry for hijacking.

~Russell

Intake change from 4-6mm bolts was April 2, 2002 (Mid year), it allowed for the composite intakes 4 - 6mm mount.

2001 are 6-6mm, earlier ones are 6-8mm.
2001 coil packs are on the valvecover as well.
2001 has EGR, only real difference I can see at all.
Looks like the 2001's ONLY hold back is EGR.

So I'm digging up a '99-'01 engine (2002's and up are scarce!)

For those looking to do an intake (and porting??) swap, Ford has the 2002 lower intake for about $160 - #2L5Z-9424-EA and the Upper (Composite) is around $105 - #2L5Z-9424-DA

The 2002 used a "dual cam profile". The cam uses a separate duration/lift on the intake and exhaust. It keeps the exhaust open longer and that may be why Ford ditched the EGR. The longer overlap may reduce emissions enough to allow them to do away with the EGR valve all together.

So the 02's and up have EGR in the cam? I've never heard of that in a gasoline engine. In diesel engines they have a Miller Cycle engine with internal EGR like that, but I dont see how it can be adapted to these, or why they would want to. Its less efficient.

Not "in the cam", but the camshaft profile was modified in '02 with a "asymetrical" profile, the intake and exhaust have different lobes, and it is heavier on the exhaust side. THis was enough that EGR was no longer required to meet standards... so I'm told.

Has hope on this died?

No, it's been done 3-4 times at least

Ok, I'm sorry. I've seen that it's been done. Doug's truck for example I've followed since he first recieved the supercharger. I was wondering if there might be an easy option still coming for those of us not so mechanically inclined without spending an additional fortune on this kit. I hadn't heard anything for a while so I thought I'd ask.

yeah...any hope on us 01 and under guys?? thx

It's all here. Find someone local to do a dyno tune and you are all set. Everything has been covered. If you have a '91-'94 check here:
http://www.rangerpowersports.com/forum/showthread.php?t=146817
'95 to '97 is similar minus the AC issues.