Explorer Intake Install

This Page is Dedicated to my Explorer intake install on a Fox 302/5.0 Mustang.

Alot of people have had questions about this install and I hope to give a basic overview of how the install is completed and what problems you might run into. If you have never removed an intake

plan for at least 2 days for the install.

 1- Power Wash your motor then strip off everything except the thermostat from the package you recieve (the parts you can not use with out heavy

      modifications are - the wiring harness,  19lbs injectors, fuel rails, and 65mm TB Elbow

 2- Unbolt the Upper from the Lower

 3- Now its time to plan at least a day for the install

 4- Disconnect all the wires from your distributor. Mark where the rotor is pointing and what position the distributor is facing

 5- Now remove the distributor

 6- Disconnect everything from your current upper intake (you can leave the wiring harness in the car)

 7- Once you have your upper out of the car unbolt your throttle body and place it to one side

 8- Now disconnet everything from your lower and unbolt it from you car

 9- Disconnect your fuel lines (remember you will need a special tool for this) and bleed out any pressure that is in the lines (have a coffee can handy)

The above steps sound easy - they are not if your car is an older/high mileage car. Everything will be brittle and the connectors are hard to get apart.

Some of the locking snaps will be broken off.

In the Photo above you will notice that the Explorer lower intake does not have the same ERG systems as a 5.0/302 Mustang.

The stock Mustang lower has the ERG hole inbetween the ports, the Explorer lower does not. The Explorer intake package that I purchased did have

 a ERG system included and I am sure with some time you could modify it to work on the Mustang.

I did not need a working EGR system on this Supercharged Mustang.

 10- Time to get dirty. Fill the motor valley with newspaper. Also fill all the head ports with newspaper

11- Scrape off all the old gaskets till you see bare metal

12- Vacume everything including the newspaper when you are done (Do not remove the newspaper yet - just vacume it)

13- Now gently remove the newspaper and take some paper towels and sop up all the oil and grit from the valley

14- Remove you fuel rails from your old lower intake. If you unbolt the rails the injectors come right out.

15- Drill the hole in the Explorer lower intake for the air temp sensor.

Mine was marked - but if yours is not just look at your old lower intake and drill in the same place.

15- Tap the hole to the proper size for the sensor

16- Install the injectors and fuel rails into the Explorer lower intake

17- Screw in the air temp sensor

18- Clean the lower intake bolt holes by running a tap threw them. Make sure you are cleaning the holes and not curring new metal.

You can tell by the way it feels - it should be faily smooth

19- Now place the gaskets on. Be careful with the front and back lower intake gaskets. My gasket kit was from FORD and they leaked.

Some people just put a whole bunch of black PVC there and wait till it gets tacky before intalling the lower - this worked best for me

20- Now go in reverse of taking your old intake off

21- Install the lower and torque the bolts down

22- Reconnect the fuel lines and other hoses

23- Install the upper intake

24- Some of the vacuum lines of the Explorer upper intake are in the front - where on the stock upper they are on the back.

Have some extra vacuum line ready. Its not a big deal

25- One vacuum line in front of the Explorer Intake needs to be plugged. Its the one in from and on top of the rest.

You cant miss it once you look at it and have the other lines installed

26- Bolt back the Throttle Body and reconnect the Throttle Cable

All Done - as you can see from these photos the Explorer Intake has much larger ports and is basicly a GT40 upper and lower.

Take it easy for a while on the car to make sure all the gaskets set. Then go get some better track times!!!

This might help you out if you have forgotten the fireing order when completeing this install. I know it helped me when we started the car and it was missing.