4bt swap -- 95 Explorer

The time has come for another engine swap in my '95 4 door 4x4.

The previous swap (SOHC/EEC-IV) isnt having problems, but the gas mileage is poor (15 MPG average over the past year).

Here's the patient (95 4 door 4x4):



And its soon to be replaced heart ('01 SOHC):



So, you may be saying to yourself, "oh boy, another 5.0l swap." The thought had crossed my mind. I have a 94 Cobra, that could use a bigger engine. Here's the 5.0 Cobra engine that could be used:



But this is my daily driver and needs to get good mileage. I work 35 miles from home. Thats 70 miles a day, 5 days a week, 50 weeks a year (2 weeks vacation) 17,500 miles a year just to get to work. Since I'm running the SOHC on the 95 EEC-IV computer, the higher compression requires me to run 93 octane.

Lets do some simple math:
20,000 miles
15 MPG
$3.75 a gallon (checked the price today on my way home)

Thats $5000 a year in fuel.


What can i swap in that makes power, get good mileage, and will last a few years you ask?



Thats right folks.... Its a Cummins 4bt!
An 84K mile,
105 HP,
265 ft-lb
3.9l turbo diesel.

She's a little rusty and the turbos got some play, but for $1200... not bad.






It also came with a Neon SRT4 intercooler and an aftermarket header.



She's clean inside!


Now, you may be saying that diesel fuel is more expensive, it will cost more to run. Most fuel estimates for this engine in a smaller truck or SUV seem to be in the 30 - 35 MPG range.

Lets take that previous number of 20K miles a year.
20,000 miles
30 MPG
$3.80 per gallon (checked today)

That works out to $2533 a year in fuel costs. Quite a bit of savings.


Now lets put all that stuff behind us and get down to the big question. Will a 750 lb, 4cyl engine fit in a 95 Explorer at stock height (or close to it) and still retain 4WD?
Good question, let see.













Looks like I will have to mod the oil pan, and make some more room for the starter. Nothing too bad. Height looks good...the hood will close. As it sits is 1/2" higher then the SOHC. So after the oil pan mods, I should be able to drop it down 2" or so. That will put the top of engine about 20 1/2" above the frame rails.
I still have to get some exact measurements front to back. Best estimate is that I'll have about 3" of clearance between the elec fan and the front of the engine.

I'm going to get some before and after weights, we have a scale at work, just have to wait till Tuesday.

remember they get the best fuel economy around 2500 rpm so a gear change might be necessary.

thats a sweet build, you should post it on TRS

Bennybooster said:

thats a sweet build, you should post it on TRS

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I think he just did.

i think he should do a build thread here!!!!

baddis said:

remember they get the best fuel economy around 2500 rpm so a gear change might be necessary.

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Try 1600-1800 RPM. They are governed at 2500 RPM stock.

I've been looking into putting Jeep 3.07s in the front. 3.07/3.08 with 31s will put me right in that range 55-75 mph.

Negative rep if no build thread here dude.

2000StreetRod said:

You are planning an interesting swap. What transmission are you considering?

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Sorry, no picks of the trans. I have a small block ZF S-542 from a F350 that i picked up a few years ago for $75.
I do have to thank Karl (kbabiak on Ex forum) for these though:



I ordered some parts.

-AC/ alt mounting bracket....$45 used. (yes, I'm planning to run A/C)
-Turbo rebuild kit.... $40
-Motor mounts... 13.44 (for both!)
-trans mount... $13.87

I also dug out some other parts:

-Sanden SD7 A/C compressor.... NIB $48.56 shipped (I bought 2 of these a while ago for an OBA setup I built.)
-Flex-a-lite 1st/2nd gen Ranger fan...... $??? no clue. (I bought it new years ago, it didnt fit my 90 4.0l w/ heavy duty cooling. i'll put it too good use now.)

adsm08 said:

Negative rep if no build thread here dude.

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How about I do a build thread on both sites?

(See edit on post 1)

those starters are huge, try a 97 powerstroke starter. Have to remove the spacer on the adapter plate for it to fit...and it will use 2 bolt wholes instead of 3 but is smaller find em on ebay for around 100 bucks

Cummins_Ranger said:

those starters are huge, try a 97 powerstroke starter. Have to remove the spacer on the adapter plate for it to fit...and it will use 2 bolt wholes instead of 3 but is smaller find em on ebay for around 100 bucks

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Yeah, I read about that on 4bt swaps. I read that the hole is a little bigger then the starter and to do it correctly you need to make a ring to align it.

Little update:

Pyrometer ordered. I'll have it thursday.

Talked to the warehouse today. I'm taking the truck over to get weighed later today.


** If anyone has a used steering rack (good or bad) they can let me use to mock this up, let me know.**

This should be cool

country0001 said:

This should be cool

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I hope so!

Cummins_Ranger said:

those starters are huge, try a 97 powerstroke starter. Have to remove the spacer on the adapter plate for it to fit...and it will use 2 bolt wholes instead of 3 but is smaller find em on ebay for around 100 bucks

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I picked up a Powerstroke starter from my starter guy to test it out. (good thing we've been dealing with him for 20 years, he said take it and see if it fits.) I need to have our machine shop cut me a sleeve to center the starter. (I can have them machine down the stock spacer, its the right ID and OD but its too long.) It spun the motor over perfect, no strange noises or grinding. Its longer and skinnier, it should clear the frame.

only real difference is its 1 tooth less. and nice and skinny to fit between the frame thank god, bc i would of had to chop the hell outa my frame to make the stock one fit