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Old 07-03-2011, 11:52 PM   #1
snoranger
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Default 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.
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'95 Explorer -- Cummins 4BT swap in progress.
2017 F150 Crewcab XLT, 5.0, 4x4, 6" lift, 35s, bent rear axle, lawn ornament until Ford can get me an axle!!!!
4BT swap thread
Ranger bed trailer build

Follow my 3 month ordeal getting parts from ford for my 2017 F150 on twitter @kevin46843488

ASE Auto and Med/Heavy Truck Master Tech.

Last edited by snoranger; 07-24-2011 at 12:59 PM.
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Old 07-04-2011, 12:04 AM   #2
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remember they get the best fuel economy around 2500 rpm so a gear change might be necessary.
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Old 07-04-2011, 12:29 AM   #3
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thats a sweet build, you should post it on TRS
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Old 07-04-2011, 12:54 AM   #4
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Originally Posted by Bennybooster View Post
thats a sweet build, you should post it on TRS
I think he just did.
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Old 07-04-2011, 12:57 AM   #5
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i think he should do a build thread here!!!!
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Old 07-04-2011, 08:51 AM   #6
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Quote:
Originally Posted by baddis View Post
remember they get the best fuel economy around 2500 rpm so a gear change might be necessary.
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.
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'95 Explorer -- Cummins 4BT swap in progress.
2017 F150 Crewcab XLT, 5.0, 4x4, 6" lift, 35s, bent rear axle, lawn ornament until Ford can get me an axle!!!!
4BT swap thread
Ranger bed trailer build

Follow my 3 month ordeal getting parts from ford for my 2017 F150 on twitter @kevin46843488

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Last edited by snoranger; 07-04-2011 at 08:53 AM.
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Old 07-04-2011, 08:55 AM   #7
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Negative rep if no build thread here dude.
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Old 07-04-2011, 09:00 AM   #8
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Quote:
Originally Posted by 2000StreetRod
You are planning an interesting swap. What transmission are you considering?
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.)
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'95 Explorer -- Cummins 4BT swap in progress.
2017 F150 Crewcab XLT, 5.0, 4x4, 6" lift, 35s, bent rear axle, lawn ornament until Ford can get me an axle!!!!
4BT swap thread
Ranger bed trailer build

Follow my 3 month ordeal getting parts from ford for my 2017 F150 on twitter @kevin46843488

ASE Auto and Med/Heavy Truck Master Tech.
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Old 07-04-2011, 09:01 AM   #9
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Originally Posted by adsm08 View Post
Negative rep if no build thread here dude.
How about I do a build thread on both sites?

(See edit on post 1)
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'95 Explorer -- Cummins 4BT swap in progress.
2017 F150 Crewcab XLT, 5.0, 4x4, 6" lift, 35s, bent rear axle, lawn ornament until Ford can get me an axle!!!!
4BT swap thread
Ranger bed trailer build

Follow my 3 month ordeal getting parts from ford for my 2017 F150 on twitter @kevin46843488

ASE Auto and Med/Heavy Truck Master Tech.
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Old 07-06-2011, 10:53 AM   #10
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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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