Explorer 302 in Mk4 Roadster

[Magic Islay Malt]

Hello, I've been viewing this forum for a long time as I plan for my build, lots of good information.
I have a specific question about using an Explorer 302 for a Mk4 Roadster.
Does anyone have a list or can link me to a list of the things I'd need to replace, I'm specifically thinking about accessory drive but also exhaust manifolds, oil filter location.
I plan to run PS, so are there special brackets and pulleys and if so, where would I source these.
I understand about springs and cams, lots of good advise for this topic, but not so much for the other parts.
Thanks in advance.

[Kivyee]

Hello, I've been viewing this forum for a long time as I plan for my build, lots of good information.
I have a specific question about using an Explorer 302 for a Mk4 Roadster.
Does anyone have a list or can link me to a list of the things I'd need to replace, I'm specifically thinking about accessory drive but also exhaust manifolds, oil filter location.
I plan to run PS, so are there special brackets and pulleys and if so, where would I source these.
I understand about springs and cams, lots of good advise for this topic, but not so much for the other parts.
Thanks in advance.

I don't know about the explorer 302 specifically, but I'll share my 302 set-up. This was done by the previous owner so I don't have specific details at the moment, but he used a march kit which has shiny mounts, alternator and PS pump. This one does NOT have a tensioner which I will probably add at a future date. I also have BBK long tube headers which fit pretty nicely.

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The oil filter is left in the stock location - I don't feel like it NEEDS to be relocated - easy enough access.
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[mrglaeser]

- The one thing I've seen discussed on Explorer Engines is if it is a version with GT40P heads you have to use different spark plug wires due to some clearance issues.
- If you are switching to carb, sniper, or similar you will need a new intake, distributor, air cleaner, coil, and wires. Fuel pump will be different if you go carb.
- You can maybe reuse the power steering pump, but you might want to look at the differences between the explorer and Mustang Pumps.
- Same scenario with the alternator.
- It looks like the Thermostat housing should work so you are good there.
- Oil pan is fine both front and rear sump pans fit.
- You might want some nicer looking valve covers (could buy in a kit with air cleaner).

-Exhaust manifold there are really three options
1. Mustang Headers + J-Pipes - lots of options here the most basic replacement headers can be found along with other options at LMR.COM
2. FFR Headers - Purchase as an option with your kit or later via website/email - if they don't show in stock call or email and you can normally still get them
3. Gas-N - This used to be a great option, they recently changed ownership and I suggest you search the forum to see the current complaints

-For accessory drive systems besides March who make nice stuff I've always liked CVF racing but haven't actually installed them
https://cvfracing.com/ford/ford-289-302-351w-small-block/serpentine-conversion-kits/

If you want a more barebones look I am personally using Speed Doctor Racing Components with March Pullies
https://www.facebook.com/profile.php?id=100057202699196
speeddoctorracingcomponents.com

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-DPcvsd7/0/LzLSmNNNKzZ7Q69wrXjCccRBGFLzJcSmnmGJ5ct2L/X2/20240803_151140-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-DPcvsd7/A)

[Blitzboy54]

World is your oyster with a 302. Endless options, but first I guess my question is how far down this engine are you looking to go? Do you just want to change the intake manifold and accessories or new cam and heads? Stock those engines were like 220 HP. You can get 350 out of one with cam and heads. If you stroke it to 347 you can get in the 425 range.

I went with a 306 on my first car out of a donor 302. Let us know some details and I can send you some ideas.

[mrglaeser]

For fun I just looked up the alternator and PS pump. Both are different from Explorer to Mustang so you would need to change those. Both can be found at any parts store or site.

[rich grsc]

Expect to have some issues with the belt wrap. I tried that and had a lot of slippage on the crank, not enough belt contact on the pulley. Had to run the belt tighter than I was comfortable with to stop the slipping

[TrackDay17]

Before I started on my build I remember watching a Youtube video from a guy called Taco Joe.
As I recall he got one out an Explorer from a junkyard and built it to put in his car originally until he could build something else budget wise.
I think he covered quite a bit of what he did and used in his videos, might check that out.
Not sure if he is active here.

[drewr]

Depending on the year, the camshaft in an Explorer 302 will be different than the 302s in Mustangs. It all depends on what you want to do with the engine. If you strip it down to the block and start over, you are golden, and you can do whatever you want. If you are planning on using the whole rotating assembly, heads, intake and fuel injection, you will be fine, but will have some limitations on above stock performance gains. Just remember, it was designed for torque in a truck.

I used a 302 from a 1995 F-150 truck, but stripped it down to the block, had a machinist clean, magnaflux, deck, hone, and bore it out to 347. Then I started with all new parts for the rebuild.

[Blitzboy54]

Before I started on my build I remember watching a Youtube video from a guy called Taco Joe.
As I recall he got one out an Explorer from a junkyard and built it to put in his car originally until he could build something else budget wise.
I think he covered quite a bit of what he did and used in his videos, might check that out.
Not sure if he is active here.

Taco Joe is great. Love his videos, he was an early inspiration for me. He really focused on the actual cost.

[mrglaeser]

Expect to have some issues with the belt wrap. I tried that and had a lot of slippage on the crank, not enough belt contact on the pulley. Had to run the belt tighter than I was comfortable with to stop the slipping

I assume you're talking about my set up here. I thought about this too, but people have been running this setup for quite sometime with out issues. I only have an hour on the engine but it seemed to work ok. I was more worried about slippage on the water pump.

[TrackDay17]

Taco Joe is great. Love his videos, he was an early inspiration for me. He really focused on the actual cost.

Agreed, I think he focused a lot on sticking to his budget although costs have increased now he did an excellent job of showing his build and the reasons why he chose what he chose.
I'm not an engine builder but his video on engine choice ws very well done.

[rich grsc]

I assume you're talking about my set up here. I thought about this too, but people have been running this setup for quite sometime with out issues. I only have an hour on the engine but it seemed to work ok. I was more worried about slippage on the water pump.

There is no reason the water pump would slip, it is the lightest load on the belt.. Remember, the crankshaft drives everything, it must power and carry the load of all the driven components

[TTimmy]

I suggest you give Mike Forte a call regarding the front accessory drive. He hooked me up with a nice setup on my 94 Mustang engine (shortie water pump and timing cover version) that included all the belts, pulleys, tensioners, alternator and PS pump. I like that is is black instead of machined billet look - I think the style works better for my build.

Mike is a great source of information and a forum sponsor. He can also help you out with many other parts you might need whether they are drivetrain related or otherwise. He can get you an engine dress up kit, EFI, etc.

See this link for more details: https://thefactoryfiveforum.com/showthread.php?51948-Cobra-Rescue-2-0-Finishing-an-Abandoned-Mk-IV&p=596700&viewfull=1#post596700

This is his setup on my Mk4:
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[BUDFIVE]

Magic-I started with a 2000 Explorer 5.0 and built a strong 347 stroker as Blitzboy54 mentioned.. its a good platform which is built for roller cams. I sold the GT40P heads and used AFR CNC aluminum 185s. I used an accessory kit from CVF Racing, including 1 wire alternator, water pump, and power steering pump (with pressure step down kit). You can find it on their website by searching for “special cobra”. If you put an EFI fuel pump in the tank and run 6AN feed and return lines to the firewall, you can choose fuel injection or carb with a regulator choice-I started with carb and have changed to sniper 2 efi in the last 2 weeks. You can check my build thread for reference: https://thefactoryfiveforum.com/showthread.php?47734-BUDFIVE%92s-CenTex-Build-A-Passenger-and-Fitting-Door-Sills
Good luck-I look forward to following your build.

[Magic Islay Malt]

Thanks everyone, appreciate your info and suggestions, lots of good stuff to look into and think about, I feel scope creep coming on and this was my first ever posting !!
Not knowing a great deal of history on the engine I bought, I am going to tear it down and have it rebuilt.
I have been talking to local machine shops here and they are all super busy, they are quoting 6 months for a basic long block refurb.
If that is the same country wide, perhaps a change of profession is in order instead of retirement.

[CraigS]

The difference between the Explorer and Mustang front dress is they wanted to put the engine closer to the radiator in the Explorer. So they shortened the water pump snout and redid all the bracketry for everything else. You could use all the Explorer stuff together and it will work just fine. The problem comes in when you want to change a pump or alt or want to get rid of some of the heavy clunky OEM bracketry. Since not too many people mod an Explorer, the aftermarket has concentrated it's efforts on Mustang stuff. I would assume that when redoing the engine you will probably also want to replace the water pump. Then you need to decide, stick w/ Explorer pump or start in on the process of switching to Mustang stuff.

[rich grsc]

I suggest you give Mike Forte a call regarding the front accessory drive. He hooked me up with a nice setup on my 94 Mustang engine (shortie water pump and timing cover version) that included all the belts, pulleys, tensioners, alternator and PS pump. I like that is is black instead of machined billet look - I think the style works better for my build.

Mike is a great source of information and a forum sponsor. He can also help you out with many other parts you might need whether they are drivetrain related or otherwise. He can get you an engine dress up kit, EFI, etc.

This is his setup on my Mk4:


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That's a nice setup, I've never see a tensioner like that before.:cool:

[Mick40]

Correct me if I'm mistaken but, didn't the Gt40 heads from an explorer needed to have the valve springs upgraded? Correct about the spark plug wires, I run a boot over mine for added protection.

Mick

[UpstateCobraGuy]

100%, better valve springs are a must! I'm running two different Explorer 302's in my builds. 17 some years on 4630RD and not a hick-up.