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Author Topic: Freaky's Official Explorer and GT-40 intake thread. 56k, don't bother  (Read 78958 times)
Freakingstang
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« on: June 02, 2005, 01:56:54 PM »

ok, this thread is designed to inform the the average mustang guru of the wonderful similarities and diffences between the GT-40 and 2 types of explorer intakes as well as the heads that came on them. I will continue to add information as I feel it is needed, or pictures to help. I will refer to the intakes as explorer 1 and explorer 2 from here on out. EXP 1 is the early 95-early 97 intake and the EXP 2 is the 97 and later. This is not an install thread. If you need help installing the intake, click here http://www.allfordmustangs.com/Detailed/614.shtml


All Explorer motors from build dates late 95 (last three months possibly four), all of 96, and the first two months of 97 come equiped with Cast iron GT-40 heads. They are the same that were on the 93-95 cobra and the 93-95 lightnings. They have 3 verticle bars on the front face of the head. These are not the "P" heads. The P heads were used from march on in 97 up to 00 or 01, whenever they quit installing 5 liters in the explorers and mountainers. The "P" heads will have 4 verticle casting bars on the front face of the heads. (front and rear corners, where the accessory bolt holes are).

Now for the intakes....
Ford had such success with the GT-40 on the mustangs, that they found a way to build a cheaper (for them) copy of the tubular. and the casting of the "Explorer" or Mountaineer" intake was born.


here is a pic of the stock 86-95 style lower
And here is a pic of the basic GT-40 lower


The Real GT-40 topside view
underside view

the three uppers from left to right GT-40, 96 explorer, 97^ explorer. Notice the similarities on the inlet tube, and the actual shape. The explorer is just an uglyier looking casting of the tubular GT-40

the three lowers from left to right are 97^, Real GT-40, and 96 explorer. Notice the intake on the left with no EGT hole on the upper flange mounting area. Also notice the #5 intake runner with no casting for the ACT hole

EXP 1 had the Same production dates....late 95, all 96, and the first two months of 97 (JAN and FEB) use the intake that is setup to run internal EGR. (NOTE= all explorers had EXTERNAL EGR, but the first go round had the provisions for internal, as they were "leftovers" from the cobra line. There will be a sticker on the intake somewhere around the throttle body inlet that will have the part number, build date and location. Every intake i have had has still had this sticker on it. EXP 2 will be from 3/97 and later.
Here is a pic of the build sticker that was on this early 97 (EXP 1)

You are going to want this intake (exp 1)if you have to pass any kind of emissions testing. This intake also has a boss in the #5 intake runner for the ACT sensor (air charge temp sensor). It will need drilled and tapped to a 3/8 NPT (national pipe thread). Also at the back of the intake, there is a boss that will need drilled for the coolant supply to the EGR space on the throttle body.
EXP 1#5 intake runner
gt-40 #5 intake runner


pic of underside of exp1 and exp2. exp 2 is on the left (non egr) and exp 1 is on the right (egr)




Now, the later 97 and on intake does not have the provisions for the internal EGR. Also, there is no boss int the #5 intake runner for the ACT. I have drilled and tapped these before, but the intake runner itself is very thin and there are not too many threads to hold the sensor in.You can either drill and tap the intake runner for the ACT, or relocate it to the air inlet piping for better temp readings. Also, in the rear passenger side where it would need to be drilled for the EGR spacer coolant line, there isn't as much material there.
 EXP 2 #5 runner



The early intake 95-96 also has a thicker flange area on the upper ( around the bolt holes that bolt it to the lower). they are about twice as thick as the later intakes. the later intakes (upper) crack quite easily (both ears of the upper on mine have been broke and rewelded. Does not affect performance, but isn't the prettiest. EXP 1 on the left and the later EXP 2 on the right
 

The later intakes 97^ are easier to find on ebay and in the salvage yards, but are not the better intake. If you are buying one on Ebay, the earlier one will bring more money. Also remember that the later intake will not work with the EGR system and probably won't pass an echeck without it. (I honestly don't know if it will pass or not, as I do not have emissions testing where I live).




Now to sum it all up, the early lower intake is the exact same part number as the lower from the GT-40 aftermarket intake. The upper is a casting of the tubular aftermarket. Where I live, They don't ususally sell the intake and heads seperately unless the motor is damaged, and at the point, you may not want the heads. Some yards will sell you the intake and heads. If they won't, check prices on the entire motor for a 1996 Explorer. Any reputable yard will ask the date. tell them 12/95 or 1/96. Keep it early. There have been some cases where ford mis matched parts like P heads with the EGR intake. I know I've priced a couple around here with 120K miles for about 400-500. At that price you get the intake, heads (GT-40's), and the throttle body. Then you can either sell the shortblock to recoupe some dollars or keep it for a spare. casting numbers for the GT-40 and EXP 1 lower are "RF-F87E-9K461-BA. The EXP 2 casting number is
RF-F87E-9K461-BB. gotta watch as they are almost the same, but only the last two letters changing.

The Explorers and Mountaineers came with a 65MM Throttle body. This will require a little work, but not much (not enought to justify spending 150+on a BBK one!)

The linkage arm on the explorer is too short to work with the mustang cable, so, if you have no use for your stock throttle body...Carefully remove the likage arm from the mustang unit and remove the explorer arm. The mustang arm should fit in the same hole. I took a drill and drilled (not too deep) a pilot hole in the ceter pivot pin (where the lever connects)for a 1/4-20 tap. I Tapped it and installed a short bolt (1/2" long) with a lock washer and a flat washer to secure the new arm. I will add some how to pics later
« Last Edit: January 01, 2006, 02:14:34 PM by Freakingstang » Logged

Steve, one of many...
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« Reply #1 on: June 02, 2005, 03:23:24 PM »

good write up, now sell me the one LOL
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« Reply #2 on: June 02, 2005, 07:31:04 PM »

You should also know that the 94-95 Cobra's lower did not have the ACT hole either since it is located right behind the mass air on those cars
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« Reply #3 on: June 02, 2005, 08:03:05 PM »

94-95 cobras had the same lower as the EXP 1 intake, it had the boss cast into the #5 intake runner, but wasn't drilled and tapped.
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« Reply #4 on: June 02, 2005, 08:06:05 PM »

94-95 cobras had the same lower as the EXP 1 intake, it had the boss cast into the #5 intake runner, but wasn't drilled and tapped.
Yep
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« Reply #5 on: June 02, 2005, 10:25:40 PM »

Can you explain that all over again? LOL

Anyway you just made some s*** clearer to me. Thanks Deal
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« Reply #6 on: June 03, 2005, 06:46:52 AM »

Nice, accurate write up.  This should be a sticky.  I run a early 97 intake/TB/injectors with the EGR provision on my car with the P heads that have been drilled for the emissions piping.
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« Reply #7 on: June 03, 2005, 10:32:13 AM »

Thanks Tom, I've got some pics to send you of some port work i'm working on.
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« Reply #8 on: June 03, 2005, 09:20:56 PM »

I feel like I could actually teach someone about this now.  Good job on the write up.
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« Reply #9 on: June 04, 2005, 01:03:50 PM »

Nice write up.  How about writing Part 2 to include port opening size comparisons. Grin
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« Reply #10 on: June 04, 2005, 06:13:45 PM »

you can't give all the secrets away
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« Reply #11 on: June 05, 2005, 11:00:36 AM »

Nice write up. How about writing Part 2 to include port opening size comparisons. Grin


 I could, but that would involve detailed pics and i don't know if my camera is up to the task of performing them.  Also, Tmoss might not be too happ... Grin
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« Reply #12 on: June 05, 2005, 06:45:30 PM »

GREAT writeup. Too late for me though. Sad I already bought a set of explorer heads and intake at Carlisle.  Good thing they're from '96! Smiley I got lucky I think. Time for some port work  Evil
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« Reply #13 on: August 09, 2005, 01:08:34 AM »

GT-40 upper looks like its got much larger runners to me :shrug:

-Will
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Freakingstang
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« Reply #14 on: August 10, 2005, 06:20:08 PM »

Yes, Looks .  But they measure the same as far as I can measure them (haven't cut one apart yet to verify in the upper high turbulance turn area.  Another reason I like the look for the unsuspecting stock look! 
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« Reply #15 on: August 10, 2005, 06:25:42 PM »

great write up freaky

p.s. the info is in the mail this week
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Freakingstang
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« Reply #16 on: December 06, 2005, 10:55:37 PM »

I am aware the pics disappeared, and am working on an updated writeup with added Cobra details.  Hopefully pics will be up soon.
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« Reply #17 on: January 01, 2006, 02:26:22 PM »

pics fixed, still working on Cobra and the 351W pics and info
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« Reply #18 on: February 24, 2006, 07:07:54 PM »

Great article. I was just going to do a write up on my Explorer engine experiment. I bought a 2000-2001 Explorer crate from my dealership. XL2Z-6006-AARM. It was on sale when I bought it at my cost for 989.00 complete, except for upper intake. I bought that from a local wrecking yard for 85.00 dollars. We put 24 lb injectors, MAC headers, Bassani Off Road Pipe, Bassani Cat Back, 75mm BBK throttle body and EGR plate. We have yet to put on the Pro-M 75mm Maf and a new air filter yet, just an old plugged K&N that I got in the mail after the project was done.

On the dyno I think it did really well. We only put in a safe tune for now with a SCT Chip. More tweeking after we get the new filter and MAF on.

220.5 RWHP at 4600 RPM.
286.4 RWTQ at 3400 RPM.
13.2 Peak Air Fuel Ratio.
12.8 Average Air Fuel Ratio.
This is all done on a Mustang Dyno MD-1750 with 91 octance fuel.

After I get the rest of the parts on, MAF & Filter, I will post the new numbers.

J


Not to shabby for a mustang Dyno.  I don't know the conversion rates, but I put down 290/330 on a dynojet with my GT-40 explorer motor.  It went a best of 12.37 @ 110.6 before numerous head gasket failures...I would think that you will pick up a ton of midrange and lowend, with no loss of topend with a 65mm TB with your setup.  There have been numerous dyno comparison between the TB's.  My TFS setup ran better and made more power with a 65 than a 75.  I never got a chance to try it out with a 70mm.  You will also see an improvement in midrange and topend with the stock H.O. cam.  The explorer cam is kinda weak, although it is a torque monster and meant to move a 5000lb truck.  You will also see an improvement in cleaning up that lower intake.  The stock casting is very restrictive, mainly in the #1 and  #5 intake runners.
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« Reply #19 on: July 08, 2008, 03:05:06 PM »

Not in the best format  Shocked - but some great info that I really needed here!
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« Reply #20 on: July 08, 2008, 07:38:41 PM »

its only been here for 3 years  Grin
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« Reply #21 on: July 26, 2008, 10:00:35 PM »

really, can't believe it is still around!
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« Reply #22 on: September 02, 2011, 12:13:41 AM »

I know this is a stupid question, but im replacing the intake gaskets & valve cover gaskets. Got everything apart & cleaned ready 4 reinstaliation. My question is which side is up on the lower intake gaskets. the side with all the graphic writing or the plain side. SOOO sorry 4 the stupid question but need an answer everythings closed too late 2 call and ask lol
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« Reply #23 on: July 16, 2013, 12:30:11 AM »

Freaky's Official Explorer and GT-40 intake thread.  56k, don't bother. What a true statement that fives assurance to what is being done.









































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« Reply #24 on: August 06, 2013, 12:15:32 AM »

The Official Explorer is the only reliable car Ford has made in years. The SUV is known to last and be efficient.













































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