TOTW: Ford 302 engine Upgrades

[Mr.N]

Welcome to the next installment of the

Topic of the Week

The subject for the week is upgrades for the Ford 302 / 5.0 engines. This is an awesome powerplant, with tons of possibilities. There are a lot of junk yard upgrades and other cheap options all the way up to the moon in prices.

Some suggested points of discussion:
- Wiring / computer
- Heads
- Intakes
- Throttle Body & Mass Airflow sensor
- Headers
- Roller vs non roller
- Stokers
- 351W block

Looking for the more basic info on swapping in a Ford engine?
See this link TOTW: Ford 302 engine swaps

[Mr.N]

Copy and paste from this thread -> http://forums.corral.net/forums/show...highlight=junk

Some Junkyard Horsepower upgrades

Throttle Body
Ford Explorer 1996-98 5.0L 65mm req. linkage modification
Save your Fox TB to use the lever in which the cable attaches.

Heads
GT40's:
93 to 95 Lightnings
93-95 Cobra
Late 95- Early 97 Explorer (not milled as much as the Cobra GT40s)
1.84/1.54, 62-65cc, labled with GT in the corner and 3 bars on the end/front

mid 97-01 Explorers = GT40P 1.84/1.48, 60-62CC, angle plug, 4 bars on the front
351W D0OE or C9AE - 69-71 351w's 1.84/1.54, 60-62cc, large straight plug
289 heads - Small chambers
D8OE 351W - (Used on trucks and 87-84 Mustangs) 1.84/1.54, large chambers, good for sc/turbo

Intake Manifold
96-01 Explorer:
96-97 explorers - cobra style intake with internal egr & IAT provisions RF-F87E-9K461-BA
97/98-00 explorers - cobra style intake with cheaper casting & no EGR & no IAT RF-F87E-9K461-BB
5/16-18 x 6" bolts x 4
5/16-18 x 1" bolts x 2
3/8" npt tap for IAT

302 EFI Truck Lower - Holley type design, fits Saleen/Vortec and several box uppers
93-95 Cobra intake
93-95 Lightning
95 Cobra R

MAF Sensor
4.6 mass air meters (2v=70mm 4v=80mm)
Lincoln Mark 8, 80mm for 24lb
90mm Lightning MAF for 42# injectors
92-95 SuperCoupe, 70mm for 36's
Ford Mustang 1994-1995 V6 or 5.0L 70mm
Ford Crown Victoria 1992-1994 4.6L 70mm
Lincoln Towncar 1992-1994 4.6L 70mm
Mercury Grand Marquis 1992-1994 4.6L 70mm
94-97 Thunderbird 4.6 70mm housing is a direct bolt on to stock fox maf bracket. ( I suspect same housing as 93 cobra. )
Also, from what I understand the sensor part# of interest is F2VF-12B579-A1A or A2A.

Alternator
Good write up with pics on the swap here
These cars have 3G 130A clocked at 12:00 and will require fox bracket notched:
94-95 GT Mustang
94-06 V6 Mustang
94-97 3.8L Thunderbird **NON-S/C**
94-97 V6 t-bird

These cars have 3G 130A or 110A in a larger case clocked where connector will be jammed under the bracket. You can make these work, but they're not the ideal 3G for fox app upgrades:
93/94-99 3.0L Taurus (not 3.8L, check the 93, this may or may not have 3G)
95-98 3.0L Windstar

Small case 3G 95A with correct clocking and correct regulator. Some have incorrect 2 groove pulley, some have correct 6 groove:
92-94 3.0L Aerostar (early 92s were 2G not 3G, so check before you buy)
96-97 F series pickup with a 7.5L

Some of these use larger cased alternator, but can work, not all 3G's were 130a, see info

Other, not sure of their clocking or output:
94-04 3.8 (-98? small case, 95a?)
3.8L 94-97 T-bird/cougar
94-96 F-150 5.0L and 5.8L came with both 130A and 95A

3G's with WRONG casing:
3.8L Windstar does not seem to have the correct housing.
3.8L Taurus

Other Electrical
The bracket and megafuse holder off of a 97 Expedition can be used in conjunction with the 3G upgrade. The bracket houses 2 175amp megafuse in seperate carriers with individual covers. Also found them on a 97 F250. Cut em down, drill two 1/4" holes and they'll mount to the coil bracket.

High Torque Mini Starters
*check B4 u buy, some years may be standard "big" starters, since these came standard on the 92/93 5.0L I'd guess they were harder to find on other cars b4 those years and easier to find after*
(1992-96) Ford Bronco 4.9L, 5.0L, 5.8L w/ AT
(1992-02) Ford E Series 4.2L, 4.9L, 5.0L, 5.8L
(1992-98) Ford F Series 4.2L, 4.9L, 5.0L, 5.8L
(1990-91) Ford LTD Crown Victoria, Mercury Grand Marquis 5.0L
(1994-04) Ford Mustang 3.8L
(1992-95) Ford Mustang 5.0L
(1990) Ford Thunderbird 3.8L/Supercharged
(1991-97) Ford Thunderbird 3.8L, (1991-93) 5.0L
(1990-92) Lincoln Mark VII 5.0L
(1990) Lincoln Town Car 5.0L

***Retrofits***
(1982-91) Ford Mustangs 5.0L (302 CID) All
(1968-79) Ford Mustangs 5.0L (302 CID) w/ AT
(1969-73) Ford Mustangs 5.8L (351 CID) w/ AT

Injectors
Ford 19lb injectors (high impedance) #s: E5TE, D5B, F78E, F6VE
96+ Explorer 5.0 has better 19's than Mustangs
Ford 21lb injectors (high) #s: D9B, F65E (305/350 GM)
Ford 22lb injectors (high) #s: FOTE-D9B (vetts and range rovers)
Ford 23lb injectors (high) #s: F7TE, F8TE (7.5L truck)
Ford 24lb injectors (high) #s: F5DE, F1TZ, F2LE, F2LE-9F593-B2A, FMS-M-9593-A302
Ford 24lb injectors Ford 93-95 Mustang Cobra
Ford 24lb injectors 93-01 Lincoln Mark 8
Ford 24lb injectors other DOHC 4.6
Ford 24lb injectors 88-97 EFI 460's F250-450 & E250-450
Ford 24lb injectors Lincoln Aviator w/4v 4.6
Ford 24lb injectors Lincoln Navigator w/4v 5.4
26lb '00 LS1 F body, maybe '99 to?, same as Ford 24's
Ford 30lb injectors (high) #s: E9SE, F1SE, F1SE-E1A (3.8SC and SuperCoupes)
Ford 30lb injectors: 95/96 Ford 4.0L Explorer & Ranger & Other
Ford 30lb injectors: 89-91 SuperCoupe
Ford 36lb injectors: 92-95 SuperCoupe
Ford 39lb 03-04 Cobra
Ford 42lb 99+ Lightning
Taurus SVO some years had 24s some had 30s

I've noticed that several of the newer 4.6L cars have a newer design thinner injector that appears squared off instead of the round bodies we're all used to*. I pulled a set of 19s in this design and found that 1 of the injectors (cylinder #4 I think) that about a 30* bend on the head of the injector. Don't know if that will cause problems with our cars by spraying the fuel at an intake wall instead of down at the piston.

Be careful if you see injectors that you think may work. If they are "Low Impedance" you can cook your computer.
vers are ribbed

Electric Fans
94+ Mustang v6
94-96 Cougar
3.8L 88-95 Taurus or
3.8L 88-94 Lincoln Continental
Lincoln Mark 8
Ford Contour and FWD Mercury Cougar dual fans
Dodge Intrepid dual fans
Grand Marquis
Ford Windstar/Mercury Villager
98-00? Mercury Mistique
Nissan Quest minivan and Mercury Villager fan is said to be a perfect fit
"seem to fit based on your level of tolerance to fabricate brackets and such from what I've read. Personally, I have a 2 spd from a 94 Villager." 1BAD6T6
Link to good writeup on changing to Mark 8 Fan

Radiator
Late 5.0 Cougars have nice alum. radiators (these fit the Mark 8 electric fans really good)

Oil Pan
Oil pan from late 90s crown vic's with 351 is a double hump design and can be used if you plan on doing a 351 conversion in your fox.

Other
Don't forget to pick up some extra relays. These cost over $10 at most auto parts stores and are pocket items at the JY. I always keep a spare in my car incase my fuel pump relay goes.

[rock-rod]

now this is going to be fun

does this thread include windsor strokers?

[Mr.N]

Originally Posted by rock-rod

does this thread include windsor strokers?

I sure hope we get a few people posting who built strokers...

I'm very happy with my 302, but someday I'd like to build roller a 392.

[Mr.N]

So, what is the biggest restriction for making power on a 302 / 5.0?

In my view it's the heads!
Even the stock Mustankg heads E7 flow is very limiting. Intake average 122, exhaust is 85 cfm.
The only thing better Ford ever sent out on a vehicle are the GT40 & GT40P. A nice upgrade for 136 intake and 97 cfm exhaust.

I've talked with a guy whos 5.0 was producing ~285 hp on the dyno, he changed from stock Mustang headers to larger aftermarket and the dyno numbers didn't change enough to notice.

Good read on heads.
http://airflowresearch.com/articles/...Part1/A-P1.htm

[Mr.N]

The nice thing about the everyone know the Ford heads are junk, you can get them cheap! Maybe even free, except for the GT40/Gt40p.

For the cost of gaskets and a few bits, try your hand at improving them.
http://www.diyporting.com/

[rock-rod]

warning: repair advice needed....

so my brandy new 351w has a bit of an oil leak.....actually it's a big oil leak.

At first I thought it was the one piece pan gasket, but I changed that out and still has the leak.

It's coming from the bellhousing. It's not the intake seal, nor the valve cover gaskets. Those areas are totally dry.

I concluded it must be a main seal. This crate motor had been sitting for about 6 years before I got it, so I figured the main seal dried out.

So I dropped the trans, removed the flexplate and block plate and...... the rear one piece main seal looks fine.

I then look above and it looks like oil has been leaking out of the driver's side cam galley plug!

WTF??

I am going to replace the plug and hope to hell that fixes it.

Talk about TEH SUCK.
I will get a few pics tonight. Talk about frustrating

[rock-rod]

Welp....figured it out. It was the cam galley plug in the back of the block. It was finger tight when I removed it.

Resealed it and no more leak.

Was able to drive the jeep down the highway at speed and I do have to say, there is a bit more torque from the 351w over the 302. It will now pull the hills rather than shift down. That alone made this swap worth it. I had the tranny out 3 times this weekend because I goofed reinstalling the converter and didn't get it seated all the way in, and when I went to turn the engine to installed the tc nuts on the flexplate, the motor would not turn over.

duh.

[Mr.N]

Originally Posted by rock-rod

Welp....figured it out. It was the cam galley plug in the back of the block. It was finger tight when I removed it.

Resealed it and no more leak.

Good to hear!

That is one heck of an upgrade!

[DEnd]

Originally Posted by Mr.N

So, what is the biggest restriction for making power on a 302 / 5.0?

In my view it's the heads!

It's the block design. Everything else can be changed.

[Stowe]

I have a '94 5.0L and have Ford Racing engine harness... is there anything I could do to the ECU to make it better? Maybe a better one or a chip?


BTW... I have a 70mm throttle body and EGR that I my wife got me for X-mas, but the wrong model, it is for pre 1993. $175 for both.

[rock-rod]

Originally Posted by Stowe

I have a '94 5.0L and have Ford Racing engine harness... is there anything I could do to the ECU to make it better? Maybe a better one or a chip?


BTW... I have a 70mm throttle body and EGR that I my wife got me for X-mas, but the wrong model, it is for pre 1993. $175 for both.

what ECU do you have?

C3W1?

If so, it's an updated version of the A9L/A9P with a more aggressive spark curve and little heavier fueling in the base map. It's a good ECU to run. Of course there is always room for improvement so finding a local chassis dyno shop with ECU tuning capabilities could garner a little more power.

[44s4ever]

Originally Posted by rock-rod

what ECU do you have?

C3W1?

If so, it's an updated version of the A9L/A9P with a more aggressive spark curve and little heavier fueling in the base map. It's a good ECU to run. Of course there is always room for improvement so finding a local chassis dyno shop with ECU tuning capabilities could garner a little more power.

hes right i put an a9l from a 91 mustang 5 speed in mine from zone rebuilt 105$ made my own harness and adjustable fuel regulator runs like a champ. 95 ho aod 60s and linked iam very satisfied

[bardenk1]

let me ask a dumb question but if you guys are getting mustang motors and swapping everything explorer over why not just start with an explorer an go from there?

[44s4ever]

Originally Posted by bardenk1

let me ask a dumb question but if you guys are getting mustang motors and swapping everything explorer over why not just start with an explorer an go from there?

mines all mustang i dont know why they are using expl stuff. im sure there is a reason. it was not near as bad to as i thought it would be made a harness just for what i needed the right length and such it works awesome, lots of power and on its side running. mine is an high output frome a 95 gt but computer from 91

[rock-rod]

Originally Posted by bardenk1

let me ask a dumb question but if you guys are getting mustang motors and swapping everything explorer over why not just start with an explorer an go from there?

it's actually the other way around. Get an explorer motor and use the mustang harness and ecu to control it.

the explorer motor is essentially a cobra 5.0l with a truck roller cam.

[cdub0451]

The Explorers had GT40P heads on them. 1.84 intake valves.

[Mr.N]

Originally Posted by cdub0451

The Explorers had GT40P heads on them. 1.84 intake valves.

Read the second post?

Originally Posted by Mr.N

Heads
GT40's:
93 to 95 Lightnings
93-95 Cobra
Late 95- Early 97 Explorer (not milled as much as the Cobra GT40s)
1.84/1.54, 62-65cc, labled with GT in the corner and 3 bars on the end/front

mid 97-01 Explorers = GT40P 1.84/1.48, 60-62CC, angle plug, 4 bars on the front

[cdub0451]

Yeah... and I have a friend who is a Ford/Mustang guru. Bought a set of D0OE heads off of him. Gotta take em to the machine shop to have a valve job done on them. I think I'm going to have bigger exhaust valves put in. Apparently according to him, the exhaust side is the biggest restriction to power in the stock "performance" heads.

[Mr.N]

Another Corral link, but it show what is needed to get 300+ HP from a 302 with GT40 parts.
Another 300+ gt-40 dyno pull

It's do-able, but if you read the thread a number of Mustang guys doubt the numbers.