get a 5.0 stang timing cover gasket set, reuse the stang timing cover....
here is the beginning of a tech article I never finished, but I'll put it up for you, it should help a lot
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Explorer 5.0 Engine swap into a Fox Body
WORK IN PROGRESS
Parts list
- 1996-2001 Explorer Long Block(must include heads and intake)
- 1986 through 1993 5.0 Mustang water pump
- 1986 through 1993 5.0 Mustang timing chain cover
- Felpro gasket kit for front seal, timing chain cover gasket, and water pump gasket part # TCS 45450
- Stock HO valve springs
- Stock HO or explorer rocker arms
- reuse your stock mustang or explorer push rods
- 86-95 HO 5.0 Cam (85-early 88 roller cams make the most power of the OEM roller cams)
- 1986 through 1993 HO Oil Pump (Explorer and Mustang oil pumps are the same, although it’s highly recommended to use a new oil pump)
- 1986 through 1993 HO Oil Pickup Tube Melling brand part number MEL-247S
- 1986 through 1993 HO Oil Pan
- 1986-1993 PCV rubber intake Grommet and Screen. NOTE: The explorer intakes do not come with the pcv screen inside the intake at the back, you must re-use your mustang one.
- FRPP Oil Pan Gasket part number FMS-M-6710-A50 or use Felpro part number XXXXXX. Both are one piece and are rubber bonded on metal.
- shorty headers that are GT40P compliant, for ceramic coated use Part Number FMS-M-9430-P51 (only if you're running a 1997-2001 Explorer engine with GT40P heads)
- FRPP Exhaust Manifold Gaskets part number FMS-M-9448-B302
- SFI approved Balancer, Powerbond makes a good inexpensive balancer part number PIO-872030. I wouldn't recommend reusing your stock balancer since it is of poor design, although it can be used if it's still in good condition.
- ALL HO Mustang accessories (smog pump, a/c compressor, power steering pump, alternator, brackets and bolts)
- EGR Spacer if you plan on keeping a functioning EGR setup(note that late 97-2001 intakes do not have EGR passages)
- 65MM+ Throttle body or modify the explorer throttle body to reclock where the throttle cable hooks on to. You can also use your stock 60mm mustang throttle body in a crunch.
- Stock HO 5.0 Fuel rails, injector harness
- ACT Sensor
- EGR coolant return line (only if you are planning on running an EGR setup)
- 9/16th drill bit and 3/8 NPT tap for the ACT sensor and EGR Coolant return line bosses (only for 1996 - early 1997 lower intakes with EGR passages). NOTE: the ACT and EGR both receive the same size tap.
Recommended Upgrades - the following are not mandatory but are highly recommended
- FRPP oil pump driveshaft - 1986-1995 EFI 5.0 part number FMS-M-6605-B302 (ARP oil pump driveshafts can be used, but they are to long and will need to be grinded down, please check for proper clearances if the ARP oil pump driveshaft is to be used)
- new water pump bolts from Ford if yours are rusty or broken off inside your old block. A full reproduction water pump bolt kit is available from Windsor-Fox.com. Do not use the ARP water pump bolt kit, as they do not come with the necessary studs.
- TFS Valve Spring Kit part number TFS-2500100 (if you plan on running a mild cam)
- Your choice of aftermarket cams. The TFS Stage 1 cam is an excellent choice, part number TFS-51402000
- Roller Rockers (use pedestal mount rockers unless you plan on removing your heads to drill for stud mount)
- Crane Roller Rocker shim kit for pedestal mount rockers, part number CRN-99170-1
- Hardened Pushrods(or reuse your stock ones), for stock length FRPP pushrods use part number FMS-M-6565-L302
Issues and Concerns
- 1996 through Early 1997 Explorers have upper and lower intakes with internal EGR passages, but late 1997-2001 do not have internal EGR passages.
- 1996 through Early 1997 Explorers have a boss on the lower intake that can be drilled out for the ACT Sensor (on intake runner number 5) and for the EGR coolant return line. The late 1997-2001 explorer lower intakes that do not have internal EGR passages, also do not have a boss for the ACT Sensor.
- 1996 through some early 1997 Explorers used standard cast iron GT40 heads and "may" be drilled for air injection internally(look for the 3 bars on the front of the head). However, note that no explorer head is drilled for the crossover tubes in the back of the heads.
- Late 1997 through 2001 Explorers came with GT40P heads and are not drilled for air injection internally(look for the 4 bars on front of the head or the GTP logo on the side of the head.)
- GT40P heads have a revised spark plug angle and require the use of GT40P compliant headers. Ford makes headers designed for the GT40P head. Standard GT40 heads do not need P compliant headers. NOTE: All FRPP headers are compliant with all ford style 5.0 heads (gt40, gt40p, etc)
- Explorers came with Hypereutectic pistons. If you plan on running boost, please keep this in mind.
- The explorer timing chain cover, water pump, oil pan, oil pump, oil pick up tube, and fuel rails can not be reused, but the fuel injectors can be. NOTE: I have heard of the fuel rails being used, but it will require line adaptors, as the fuel lines are in the rear. (I've heard the SN95 5.0 cars may have this style from the factory, but I can't verify this.) For simplicity, it's much easier to use your fox rails.
1997 Explorer 5.0 into an 86 GT Convertible