My 2003 FX4 Level II 5.0L V8 swap pictures [Archive]

rwenzing

Dec 02 2007, 10:14pm

Explorer 5.0L, 4R70W transmission and BW4406 manual transfer case, fresh from the junkyard:

http://www.rangerpowersports.com/gallery/data/500/medium/Parts_run_004.jpg

On the stand:

http://www.rangerpowersports.com/gallery/data/500/medium/progress_001.jpg

Dropping it in:

http://www.rangerpowersports.com/gallery/data/500/medium/V8_dropping_in_012.jpg

Completed engine bay:

http://www.rangerpowersports.com/gallery/data/500/medium/V8_engine_bay_4.jpg

http://www.rangerpowersports.com/gallery/data/500/medium/V8_engine_bay_5.jpg

http://home.comcast.net/~rwenzing/V8_engine_bay_lg.jpg

Ranger transfer case shifter on modified F150 linkage:

http://www.rangerpowersports.com/gallery/data/500/medium/trans_transfer_case_008.jpg

Explorer 4R70W transmission with F150 BW4406 transfer case and F150 front driveshaft:

http://www.rangerpowersports.com/gallery/data/500/medium/trans_transfer_case_016.jpg

PS Header:

http://www.rangerpowersports.com/gallery/data/500/medium/V8_headers_009.jpg

302 hood badges:

http://www.rangerpowersports.com/gallery/data/500/V8_302_emblem_installed.jpg

Transfer case shifter and Explorer Center Console:

http://www.rangerpowersports.com/gallery/data/500/medium/Explorer_console_003_sm.jpg

Explorer EATC climate control and trip computer:

http://www.rangerpowersports.com/gallery/data/500/medium/center_dash_004.jpg

http://www.rangerpowersports.com/gallery/data/500/2006_corners_truck_view.jpg

Powertrain
5.0L V8
4R70W Transmission
BW4406 Manual Transfer Case
4.10 Torsen Rear Diff
Aussie Locker up front
Torque Monster Headers
Magnaflow duals
SLP Thunderbolt Airbox

Chassis
Bilstein 7100 reservoir shocks front and rear
Mustang SVO/Cadillac rear disc brakes
James Duff traction bars
Front and rear sway bars
Sway bar disconnects
Explorer IRS diff cover
Alcoa forged aluminum wheels
31x10.50x15 BFG ATs

Exterior
Keypad entry
Heated Mirrors
Dual rear LII tow hooks
Black Headlight Background
06/07 Corners w/Black Background
06/07 Ranger Emblems
06/07 Ranger Taillights

Interior
Heated seats
Explorer EATC Climate Control
Explorer Limited Steering Wheel w/Controls
Explorer Overhead Console
Explorer Center Console w/Message Center
Explorer Autolamps and Autodimming mirror
Real oil pressure gauge mod from 95 Ranger
Audible low oil pressure alert
Pushbutton door chime disable
Pushbutton ABS disable
Autometer pillar pod with A/F and EGT gauges
Door lock status LEDs
Bullitt Mustang pedals

EDGEUCATOR

Dec 02 2007, 10:31pm

Dang Bob! Way to go! Super clean install! Can't beat the 4404 transfer case route!

Bad One

Dec 02 2007, 10:44pm

Watched this over on R-F, Bob. Looks OEM, as usual:thumbsup:

mrchocpudding

Dec 02 2007, 10:50pm

very nice...i love the center console too...i like the screen that tells you how much gas you have left. Very unique and cool

rwenzing

Dec 02 2007, 11:08pm

i like the screen that tells you how much gas you have left. Very unique and coolFord calls it the "Message Center" and it has a bunch of functions. These are the ones I can remember right now:

Trip Computer
Fuel left
Fuel used
Distance traveled
Distance to empty
Instantaneous fuel economy
Average fuel economy

Systems Monitor
Charging system
Low oil level
Low fuel level
Low washer fluid level
High coolant temp
Oil change reminder

Selectable metric or English units. A diagnostic mode is also available for troubleshooting.

http://home.comcast.net/~rwenzing/display_charge_sm.jpg http://home.comcast.net/~rwenzing/display_dte_sm.jpg

http://home.comcast.net/~rwenzing/display_avg_mpg_sm.jpg http://home.comcast.net/~rwenzing/display_ROM_level.jpg

http://home.comcast.net/~rwenzing/Message_Center_sm.jpg

redranger04G

Dec 02 2007, 11:11pm

also saw this on R-F bob, good work

Bloo

Dec 02 2007, 11:13pm

Now that's impressive!!! Most impressive!!!

Shadow Edge

Dec 02 2007, 11:14pm

:o: Wow ... how jealous I am right now! Extremely well done and top-knotch craftsmanship! How 'bout a video?

Bad One

Dec 02 2007, 11:29pm

:o: Wow ... how jealous I am right now! Extremely well done and top-knotch craftsmanship! How 'bout a video?

He does... or did. I've got a video of his truck at idle with a walk around and a 0-80 pull. Probably watched it 10 times... lol

Ranger72

Dec 02 2007, 11:38pm

Very nice man! OEM look as always!

yetti96

Dec 03 2007, 12:07am

Wow. I wonder how difficult the message center was to install and get working correctly.

rwenzing

Dec 03 2007, 12:14am

Wow. I wonder how difficult the message center was to install and get working correctly.As you might guess, there are a ton of wire connections to make. As far as I can tell, none of the Ranger PCMs output the necessary fuel flow value that the trip computer needs to do the fuel economy calculations. I was able to make it work in my truck because I'm using an Explorer PCM that is set up for it.

MichiganSpecial

Dec 03 2007, 12:31am

:ho: ahaha. That "message center" IS very unique.

ben_2_go

Dec 03 2007, 12:42am

That's sexy but now I'm sad.My 01 Ranger ain't got no V8 and my 90 Cougar has a 3.8 and digital cluster and message center.To bad it's too out dated and under powered.Truck looks all factory.That's the way a fully loaded Ranger should look and perform.

fordnut_302

Dec 03 2007, 12:52am

Nice install,:headbang: I wish I took my time and done mine right.:sad2:

RangerRaider

Dec 03 2007, 12:54am

Damn man, looks perfect. How many hours did you put into that?

rwenzing

Dec 03 2007, 07:41am

Damn man, looks perfect. How many hours did you put into that?With the exception of shortening/balancing the rear driveshaft, I did 100% of the work myself. Side projects like the console/trip computer and converting from the Explorer's full time AWD to manual part-time 4WD stretched the work out for a few months - I couldn't even guess at the number of hours.

KIMO

Dec 03 2007, 07:46am

man, awesome job ! thats all I can say , awesome !!!

pinellas50

Dec 03 2007, 07:49am

Outstanding job!

basa820

Dec 03 2007, 08:09am

is there a write up on this? I wanted to do av8 swap, but no one had done a v8 swap on a 01+ranger. that's what stopped me from doing it. now I already spend 4k rebuilding my 4.0 :(
*never mind, u don't have the new style cluster that the 04's do.

Ford Fanatic

Dec 03 2007, 08:16am

As usual nice work!

patatewz

Dec 03 2007, 08:48am

... :)

just to cool.

Black Widow '90

Dec 03 2007, 08:50am

awesome bro, job well done :)

85coupe50

Dec 03 2007, 03:20pm

WOW I just went over there for the first time and read the entire thread. That is one impresive truck you have built and you have some MaD fAb SkIlLs there... Love that truck.

I hope to get a EFI V8 Ranger going here sometime in the near future. I am glad it will not be my daily driver until it's complete.

Matt

400sxman

Dec 03 2007, 05:12pm

WOW, that looks amazing, i truly am jealous. do you think you could do a write up on how to convert from the explorer's AWD to selectable 4WD out of an f-150. i know I've been dying to do this and i'm sure there are a bunch of other explorer drive train guys here that feel the same way. it'd be sweet to get the better fuel mileage (as well as be able to do donuts). once again, it looks awesome man,
~Nat

red85

Dec 03 2007, 06:40pm

So clean! Makes my swap sure look like a hack job LOL Beautiful workmanship and great attention to detail. I'd like to see that truck with a vortech blower on it too... Great job!

rwenzing

Dec 03 2007, 07:00pm

do you think you could do a write up on how to convert from the explorer's AWD to selectable 4WD out of an f-150. i know I've been dying to do this and i'm sure there are a bunch of other explorer drive train guys here that feel the same way. The 5.0 AWD Explorer guys came up with the BW4406 manual case swap and I adapted it to my Ranger. The 4406 was used on 97~2003 F150s and you'd also need the front driveshaft and manual shift linkage from the same donor. The 4406 case and linkage bolt right up to the 4R70W extension housing and a conversion U-joint will mate the F150 driveshaft to the stock Ranger front diff.

There are only 2 real differences for the Ranger application:
The Explorer swap uses a stock Navigator/Expedition rear shaft. I couldn't easily find an off-the-shelf rear driveshaft that was the right length for the Ranger. Instead, I had my stocker shortened about a foot with a new fixed yoke at one end. then I used a slip yoke from a 06 Expedition/Navigator to link the shortened shaft to the 4406.
The BW4406 is larger in every dimension compared to any of the Ranger or Explorer cases. The Ranger's frame is narrower through the middle than the Explorer and that makes clearance from the t-case to the LH frame rail way too close for my tastes. I moved the entire powertrain about 1/2" toward the passenger side to get some daylight between them. I'm sure there are other ways to deal with this issue but that's what I did.

How-to describing the Explorer 5.0/AWD to 4406 swap:
http://www.explorerforum.com/forums/showthread.php?t=166726

A brief explanation of what I did make the t-case fit my Ranger:
http://www.ranger-forums.com/forum2/showpost.php?p=694604&postcount=71

Ranger driveshaft mods for the 4406:
http://www.ranger-forums.com/forum2/showpost.php?p=706224&postcount=102

trailhead00

Dec 05 2007, 08:09am

I remember the day I started mine for the first time. Man it still makes me smile have the 302 under the hood. People still look as you drive past when they hear that rumble they cant help but wonder whats under the hood...Very very nice job man. Props!!!!

BrianB31

Dec 05 2007, 10:54am

Very nice, very nice indeed. :)

Martinarcher64

Dec 05 2007, 10:56am

:drool: Nice work. Looks like it came from the factory.

2.3'dranger

Dec 05 2007, 11:10am

I've been waitign for yo uto poast this for like 3 months now.. i saw pics on ur car domai and was like omg.. its look super clean and you now have my fav 4wd ranger... all the oem+ touchs and eveything just make it awesome in every way... good job.. now get some vid of that thing in action...later

1994 rad ranger

Dec 06 2007, 11:23am

what is the yoke from i need to know right away cus im drivein a fwd explorer not cool at all. All though there aren't may of them!

fire ranger 18

Dec 06 2007, 11:54am

what kind of millage are you getting

rwenzing

Dec 06 2007, 02:03pm

what is the yoke from i need to know right away cus im drivein a fwd explorer not cool at all. All though there aren't may of them!I'm not sure what you're asking. The yoke on the custom rear shaft is a Spicer yoke that the driveshaft shop supplied and welded in.

rwenzing

Dec 06 2007, 02:07pm

what kind of millage are you gettingI haven't taken any long trips to check it. According to the trip computer, it's 20~21 MPG at 55 MPH and about 17~18 MPG at 70 MPH.

Wheat

Dec 06 2007, 02:18pm

Very well done..

1994 rad ranger

Dec 06 2007, 11:55pm

im lookin for the yoke it self what dose it come from year model or part number

fire ranger 18

Dec 07 2007, 06:09am

rwenzing

Dec 07 2007, 07:03am

do you think there is enough room to squeeze in a standerd, is there even one avalable, and do you think the stock axels are up to the task. the reason I ask all this I am considering a simular project A 7.5" Ranger axle is iffy with a 5.0 (Ford doesn't even use it with the 4.0). A stock 28-spline 8.8" Ranger axle assembly should be OK with a stock 5.0 if not abused. A 31-spline 8.8" Ranger or Explorer assembly would be better.

~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

I'm not an expert on V8 Ranger manual swaps but there are 4 options I would consider:

M5ODR2 5-speed manual: this transmission was used in several Ford applications but had the correct bolt pattern in F150s behind 4.2L and 5.0L's. The bell housing is integral to the main case so there is no option of swapping bell housings to other versions of the R2 to get the correct 302 pattern. The R2 uses a hydraulic clutch slave that is probably compatible with the stock Explorer/Ranger hydraulic clutch components. There were a couple of different shifter positions over the years so it would pay to measure the donor for fit. Available in 4x4 and 4x2 versions. Readily available in junkyards and reasonably cheap.

ZF 5-speed manual: Used in many gas and diesel apps. The version used in F250/350's with the 302 or 351 should bolt to any 302. Uses a hydraulic slave cylinder. Available in 4x4 and 4x2 versions. Advantage - strength. Disadvantages - expensive, hard to find and usually high miles since the small block version has been out of production for several years. It is a real truck transmission and has a reputation for gear noise. Also, the transmission is large and may not fit under the Ranger transmission tunnel without a body lift.

T-5 5-speed manual: Made in several versions with a variety of torque capacities so it pays to shop for one rated at 300 lb-ft or higher. Bell housings to match the 302 are readily available. Problems: Rearward shifter position compared to stock Ranger. Cable clutch actuation will require fab work or a hydraulic adapter kit. No Ford versions were made with a 4x4 extension housing. However, the word is that a Chevy S10 extension housing will fit for 4x4 apps.

Tremec 5- or 6- speed manual: 3 optional shifter kits should put the shifter where needed. Hydraulic or cable clutch kits are available. Bell housings to match the 302 are readily available. Not sure about 4x4 adaptability. A very good transmission but may be hard to find in good used condition. Not cheap new or used.

tony

Dec 07 2007, 07:32am

what is the yoke from i need to know right away cus im drivein a fwd explorer not cool at all. All though there aren't may of them!
the ex yoke is different from any old ford i have seen get 1 from an ex and get your shaft in

rubydist

Dec 07 2007, 09:27am

rwenzing

Dec 07 2007, 12:46pm

As usual, a great job, Bob!

I just have a couple of questions:
1. Did you retain the air conditioner? Any mods to the airbox, etc. that were needed?
2. I'm curious why you had the grill/headlights/etc. off for the swap??
3. I think I'd like the AWD transfer case. Other than no "low" range, is there any disadvantage to that in your mind?

Thanks for sharing your good work!
1. Yes, the A/C works fine using the original Ranger compressor. In fact, it is all original Ranger parts except for the Explorer 5.0 tube/hose manifold that mounts to the compressor. The manifold is a different shape to match the compressor location on the V8. Nothing else needed modification.

2. To prevent damage to those parts during the swap and to get my smallish engine hoist in close enough for the engine drop. It was also convenient to have grille, bumper and valance out of the way when mounting the transmission lines and cooler.

3. According to what I've read on the Explorer boards, the AWD reduces fuel economy and increases tire wear. On the plus side, handling is more predictable in wet weather.

Many others have swapped in the Explorer 302/AWD with good results. For my project, I definitely wanted low range so there was no question about the swap from AWD to a part time 4WD case.

fire ranger 18

Dec 07 2007, 01:28pm

is there a way or some sort of a chart that has what axles are in what vehicals? when I get to do this I want to do it right and don't want to redo it. haha

rwenzing

Dec 07 2007, 01:51pm

is there a way or some sort of a chart that has what axles are in what vehicals? when I get to do this I want to do it right and don't want to redo it. haha

http://www.rangerpowersports.com/tech/?p=76
http://www.therangerstation.com/tech_library/Axles.html

ddranger

Dec 07 2007, 04:16pm

i've only got one thing to say about it

:drool: :drool: :drool: :drool: :drool: :drool: :drool: :drool: :drool: :drool: :drool: :drool:

1994 rad ranger

Dec 08 2007, 09:53am

what year ex

gt40

Dec 08 2007, 10:38am

Nice Job, Bob :thumbsup: :thumbsup:

BlueMan

Dec 08 2007, 10:54am

I just saw this post and it's a perfect looking job - I think the SVO team doing up a one-off 5.0 4x4 ranger for SEMA wouldn't have done better. I don't envy you on changing the plugs though - looks a little snug! I like the manual 4x4 high/low lever too - I was never a fan of the electric switch.

gt40

Dec 08 2007, 10:59am

I've a similar setup - 93 cougar engine w/TM headers - the plugs are not that hard to get to, but my engine sits a little more forward from what I can tell.

rwenzing

Dec 09 2007, 04:41pm

Thanks, everyone, for the positive comments! It has been a challenging but fun project and there should be more to come.

menghi06FX4II

Dec 09 2007, 07:56pm

That all looks like it came there from Ford itself... EXCELLENT install!

How's the feeling of it?

RangerHaver

Dec 09 2007, 11:08pm

Eventually I want to do a major makeover on my truck. I was originally planning on bags and maybe bodydrop (or at least a Z)... but now I may do an ex V8/BW4406/SAS. Very nicely done... awesome truck.

rwenzing

Dec 13 2007, 08:23pm

How's the feeling of it?It was a 4.0 manual before the swap, so in some ways it is completely different but in others exactly the same.

A stock Explorer 5.0 doesn't make much more peak horsepower than the Ranger 4.0 but the specs say it has about 50 lb-ft more at the torque peak. It is so much more responsive below 3500 RPM which is where the 4.0 felt a little weak by comparison.

I love it!

Disranger

Dec 14 2007, 03:06am

rwenzing

Dec 14 2007, 07:45am

Nice swap!

So how was installing the 4r70w? I have been thinking of swapping over from my c4. Sucks not to have OD. Also how are you shifting the trans? I don't see a floor or colum shifter anywere. I see just the manual transfer case shifter.Mine uses an Explorer column shifter and cable. The 99 Explorer 4R70W and 5.0L are a direct bolt in on the 2003 Ranger mounts. Mine is electronically controlled by the Explorer's engine PCM as in the original application. If you don't want to use an Explorer PCM with your engine for some reason, Baumann makes a standalone 4R70W control unit kit. It's about $500.

http://www.becontrols.com/products/electronicscat.htm

fire ranger 18

Dec 14 2007, 08:13am

if I go with a man trans will I have any trouble using the computer out of a auto ex or will it want to control a trans that is not there

freddie

Dec 14 2007, 12:04pm

WOW I know I've complimented you before, but man it's sooo nice! I plan on starting the same swap on a superlifted 2000 in a few months, and I'm aware that driveshafts will definitely need custom made then, and that won't be fun. Ha I'm serious when I say this: I might ask you for your phone number incase I get lost in this and need "immediate" help.., lol. If you've got any detailed info on this, I'll take it.. Your truck is amazing, evrything about it looks OEM, congrats.

By the way, what's your phone number? Haha kidding(for now),

Droop1120

Dec 19 2007, 11:54pm

wow, this truck is absolutely beautiful, quite possibly the most beautiful ranger i have ever seen. The interior mods from the explorer are awesome. just one quick question if you don't mind answering it,About how much did the engine, transmission, and transfer case run you from the junkyard?

Disranger

Dec 20 2007, 12:22am

Mine uses an Explorer column shifter and cable. The 99 Explorer 4R70W and 5.0L are a direct bolt in on the 2003 Ranger mounts. Mine is electronically controlled by the Explorer's engine PCM as in the original application. If you don't want to use an Explorer PCM with your engine for some reason, Baumann makes a standalone 4R70W control unit kit. It's about $500.

http://www.becontrols.com/products/electronicscat.htm

Yea the Baumanns are nice. I wanted to find a way to use a floor shifter. I currently have a c4 with hurst 1/4 stick. I like it that way. Might have to go AOD to get OD and floor shift. If I did use a 4r70w, I would definitly the stock pcm as I am now and keep it fully electronic.

rwenzing

Dec 20 2007, 01:59pm

About how much did the engine, transmission, and transfer case run you from the junkyard?
Complete engine, y-pipe and cats $314
Transmission $99
Transfer case $170

That was the good news. I spent a lot more than what that totals up to on other stuff for the swap. My opinion is that it would have been better to find a good deal on a complete crashed Explorer donor than to buy it piece by piece. I got tired of looking for that elusive "good deal", so that's why I did it the other way.

BlueBull

Dec 21 2007, 07:51am

I'm very jealous. I'm going to be getting a lil jap car for a daily driver and truck will soon become the project truck that I can have out of commission for a couple days/weeks at a time. I plan to to do the same swap, and convert to 4x4 after. Since I have an edge, the 4x4 swap (straight axel) should be a little easier.

I wanted to ask, how hard is the computer swap? just plug and play? I'm pretty clueless when it comes to that stuff.

rwenzing

Dec 21 2007, 10:11am

I wanted to ask, how hard is the computer swap? just plug and play? I'm pretty clueless when it comes to that stuff.The Explorer PCM, wiring harness, trans and engine go in without too much trouble. However, there are electrical changes that need to be made for any 5.0 Ranger swap. Swaps into 98~2000 Rangers are probably easiest but 2001+ can be done.

Read this stickied thread to see what needs attention on the electrical end for 2001~2003:
http://www.rangerpowersports.com/forum/showthread.php?t=186450

And here's another for 98+ Ranger 5.0 swaps in general:
http://www.rangerpowersports.com/forum/showthread.php?t=170886