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  #16  
Old 08-27-2016, 09:51 AM
JAMMANICA JAMMANICA is offline
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Default Re: Thee Gherkin build, 5.0

Cleaned exhaust gasket surfaces in prep for the headers, scraped cups of crud off the motor in general then was trying to scotchbright some of the corrosion off the mushroom (3M rolock disks and an angle grinder).

Got a little carried away. Makes me want to take it off and finish it up. Naaa.

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00 XLT 4WD XCSB 4.0 my new baby
00 XLT 2WD RCSB 5.0 swap in progress.
98 XLT 4WD XCSB 4.0 dead
99 EXPO donor motor for dead one and parts for the others.
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  #17  
Old 08-27-2016, 10:21 AM
horizon94 horizon94 is offline
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Default Re: Thee Gherkin build, 5.0

Looking good. If you keep cleaning everything up you'll have a stock-like look when you're done!

Sent from my SM-N910V using Tapatalk
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  #18  
Old 08-29-2016, 09:43 AM
JAMMANICA JAMMANICA is offline
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Default Re: Thee Gherkin build, 5.0

The dude I got the headers from says it's OK to blow his cover LOL here's the link to his FB page:
https://www.facebook.com/BigWhiteExplorer/

Looks like he supercharged too, really cool ride. I'm hoping he upgrades his supercharger some day
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00 XLT 4WD XCSB 4.0 my new baby
00 XLT 2WD RCSB 5.0 swap in progress.
98 XLT 4WD XCSB 4.0 dead
99 EXPO donor motor for dead one and parts for the others.
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  #19  
Old 08-29-2016, 07:43 PM
JAMMANICA JAMMANICA is offline
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Default Re: Thee Gherkin build, 5.0

While waiting on the headers, I took the EGR off (going to make my own cover) and started working on the oil filter relocation hardware.
I bought a Hayden 291 kit as suggested on another forum.

Well it didn't work out quite like I thought. I put the screw on adapters in the block, screwed the aluminum manifold on... stood off the block by about 1/8".

So here is another boring array of pictures describing what I did to remedy the situation.

First the hardware box:



Removed the center screw thingy (no idea what it is called) from the block with a 1-1/4 socket. The original water cooled oil filter mount mounted to this. It needed to be at least 1/8" shorter for the o-ring to touch the lip on the block.



Side shot:



A few RPM's later and a little bit of carbide, took off exactly 1/4"



This is what the center fitting (black) and the outside fitting (silver) looks like:



Putting it all together:



and:



Re installed on the block:



The manifold from the underside:



Success! We have o-ring contact:



I was lucky to get it pointed in the direction I wanted the first time. If it was in the wrong direction taking more off the lip in the second/third/fourth pic would make it stop sooner in the rotation. Distance between threads would be 360 deg. of rotation, half 180, bla bla bla.

Anyhow I don't know if this was an issue for anyone else doing a conversion and perhaps there is a more friendly manifold than the hayden but it works and I can put the second half just about anywhere I want.
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00 XLT 4WD XCSB 4.0 my new baby
00 XLT 2WD RCSB 5.0 swap in progress.
98 XLT 4WD XCSB 4.0 dead
99 EXPO donor motor for dead one and parts for the others.
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  #20  
Old 08-31-2016, 09:09 AM
JAMMANICA JAMMANICA is offline
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Default Re: Thee Gherkin build, 5.0

They're heeeeeeeerrreeeeee........


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00 XLT 4WD XCSB 4.0 my new baby
00 XLT 2WD RCSB 5.0 swap in progress.
98 XLT 4WD XCSB 4.0 dead
99 EXPO donor motor for dead one and parts for the others.
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  #21  
Old 09-22-2016, 06:50 PM
JAMMANICA JAMMANICA is offline
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Default Re: Thee Gherkin build, 5.0

Project going SLOOOOWWWWW

Vacation

Did the IMTS in Chicago

Catching up on yard work, house work.

Only progress, found a stripped out bolt hole in one of the header flanges. I hate helicoils so I went full blown Keensert.

I plan on getting the motor bolted to the trans and the headers mounted next week, then on the weekend I'll have some help shoehorning it in the ranger Still need a yolk to fit the 2WD trans but want to measure overall length to see if I need to shorten the driveshaft or not. If the trans mount on the V8 trans lines up with the holes in the crossmember it looks as if I can use the ranger driveshaft with a new yolk at the trans as is. I really want to drive this thing a few times before winter hits hard. Then I'll make the 8.8 rear end swap a winter project.

__________________
00 XLT 4WD XCSB 4.0 my new baby
00 XLT 2WD RCSB 5.0 swap in progress.
98 XLT 4WD XCSB 4.0 dead
99 EXPO donor motor for dead one and parts for the others.
Ford Enthusiast
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  #22  
Old 10-16-2016, 02:05 PM
JAMMANICA JAMMANICA is offline
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Default Re: Thee Gherkin build, 5.0

Headers on, oil dipstick had to be bent unusually to accommodate the headers.

Had he wrong motor mounts, why didn't anyone warn me LOL?

A coil spring ranger needs expo 4.0 engine mounts bought and 2 adapter plates made, I have the prints for the plates and will make extras.

Didn't get the motor in because of that little detail. Maybe next weekend.
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00 XLT 4WD XCSB 4.0 my new baby
00 XLT 2WD RCSB 5.0 swap in progress.
98 XLT 4WD XCSB 4.0 dead
99 EXPO donor motor for dead one and parts for the others.
Ford Enthusiast
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  #23  
Old 10-29-2016, 01:05 PM
JAMMANICA JAMMANICA is offline
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Default Re: Thee Gherkin build, 5.0

Well through the wonder of research I found out the driver side mount is virtually impossible to find, passenger side about 20 bucks. ALSO for everyones reference on a coil spring ranger previously with a 2.5 THE 2.5 PASSENGER MOUNT IS IDENTICAL TO THE 4.0 so no need to break the virtually new shock off or snap the sway bar link trying to get it loose to drop the spring and put an identical motor mount on. Meh.

Found a guy on e-bay with the mount plates, I didn't have to make them.

So now I have bought new shocks, new sway bar links, articles said I needed a stamped metal oil pan for clearance instead of the cast aluminum oil pan so I bought one of those.

While the pan was off I noticed everything looked GREAT except for the timing chain, had enough slop in it that I am replacing it.

I really really wish someone who has done this swap before would have stepped in and shouted "Jim, you are doing it wrong. The mounts you said you bought won't work, the original plates on the motor have to be swapped out, you need a stamped steel oil pan AND you can use the passenger side mount as is if it is not busted you dummy".

I can take it, go ahead.
__________________
00 XLT 4WD XCSB 4.0 my new baby
00 XLT 2WD RCSB 5.0 swap in progress.
98 XLT 4WD XCSB 4.0 dead
99 EXPO donor motor for dead one and parts for the others.
Ford Enthusiast
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  #24  
Old 11-06-2016, 09:41 AM
JAMMANICA JAMMANICA is offline
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Default Re: Thee Gherkin build, 5.0

OK right mounts in.

Since last post I have on the way:
True double roller chain and gear set w/torrington roller thrust bearing

Melling high volume oil pump

Might as well replace it while It's out and on a stand.

Was thinking should I get a water pump... the old one is working fine and not leaking BUT the motor is out and it is real easy to get to plus I'm going to have it off anyway for the t-chain and gears.

Isn't there a "better" water pump that has less drag than a standard one? Back in 86 I saw one for my mustang but a little research turned up nothing for the 97 mountaineer.
__________________
00 XLT 4WD XCSB 4.0 my new baby
00 XLT 2WD RCSB 5.0 swap in progress.
98 XLT 4WD XCSB 4.0 dead
99 EXPO donor motor for dead one and parts for the others.
Ford Enthusiast
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  #25  
Old 11-12-2016, 11:43 AM
JAMMANICA JAMMANICA is offline
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Default Re: Thee Gherkin build, 5.0

So today is a all ranger all day.... day

I put the new super double roller timing chain with roller thrust bearing and someone tell me if this is normal:

__________________
00 XLT 4WD XCSB 4.0 my new baby
00 XLT 2WD RCSB 5.0 swap in progress.
98 XLT 4WD XCSB 4.0 dead
99 EXPO donor motor for dead one and parts for the others.
Ford Enthusiast
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  #26  
Old 11-13-2016, 07:37 PM
JAMMANICA JAMMANICA is offline
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Default Re: Thee Gherkin build, 5.0

Test fitting, pulled again absolutely nothing lined up. Having to slot one bracket over an inch before I can bolt it down to check clearances.

The article that says "plug and play" is deceiving I am considering it a custom build from here forward. I have been able to get very little reliable information from anyone.


__________________
00 XLT 4WD XCSB 4.0 my new baby
00 XLT 2WD RCSB 5.0 swap in progress.
98 XLT 4WD XCSB 4.0 dead
99 EXPO donor motor for dead one and parts for the others.
Ford Enthusiast
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  #27  
Old 11-17-2016, 09:37 AM
BlueOvalGuy92 BlueOvalGuy92 is offline
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Default Re: Thee Gherkin build, 5.0

Looking good my friend, keep up the good work!!
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  #28  
Old 11-18-2016, 11:59 AM
JAMMANICA JAMMANICA is offline
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Default Re: Thee Gherkin build, 5.0

Bought a non HP cloyes. Much more satisfied.....

__________________
00 XLT 4WD XCSB 4.0 my new baby
00 XLT 2WD RCSB 5.0 swap in progress.
98 XLT 4WD XCSB 4.0 dead
99 EXPO donor motor for dead one and parts for the others.
Ford Enthusiast
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  #29  
Old 05-31-2017, 12:06 PM
JAMMANICA JAMMANICA is offline
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Default Re: Thee Gherkin build, 5.0

Back at it. Looked lonely out in the yard so it motivated me to start again.



Put timing chain cover and stamped steel oil pan on. Ready to drop in now. Maybe I'll complete it this year.








__________________
00 XLT 4WD XCSB 4.0 my new baby
00 XLT 2WD RCSB 5.0 swap in progress.
98 XLT 4WD XCSB 4.0 dead
99 EXPO donor motor for dead one and parts for the others.
Ford Enthusiast
Reply With Quote
  #30  
Old 09-02-2017, 05:58 PM
JAMMANICA JAMMANICA is offline
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Default Re: Thee Gherkin build, 5.0

OK if anyone still cares

I put the new engine plates in today, was able to get the motor on the mounts, put the transmission in and was able to get the crossmember in just fine.

So trans and engine in and fit well. Finally.

Many things left to do but it is back on the front burner.
__________________
00 XLT 4WD XCSB 4.0 my new baby
00 XLT 2WD RCSB 5.0 swap in progress.
98 XLT 4WD XCSB 4.0 dead
99 EXPO donor motor for dead one and parts for the others.
Ford Enthusiast
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