My remote turbocharged 2000 Explorer 5.0

[Explorer5.0]

I just wanted to show off my DIY remote build. The truck is an AWD 2000 5.0 Explorer- I like to think of it as an AWD SUV Mustang. This truck actually was lifted with tube bumpers, safari rack, and 32" ATs on 20" wheels just a few months ago- it has undergone a big transformation here lately. It is now lowered slightly in the front with the rear at stock height(with sagging springs). I kept the same wheels but put smaller tires on them and added 2" spacers. Now onto the turbo...

The Turbo is a T04E .50/.63 which turned out to be perfect for remote mounting. If I ever decide to insrease boost, it can be replaced easily. I am using the stock exhaust with muffler delete to the turbo, then a 3" tailpipe. In the tailpipe is my AEM wideband o2 sensor. For charge pipe, I bought 2" mandrel bent intercooler kit from one of the sites sponsors along with some 2" pipe from my local muffler shop. For couplers, I am using cut pieces of 2" ID radiator hose. It can be bought from Advance Auto pretty cheaply- I got one piece that was a large 90 for $13 and had some left over. I just cut it into the desired length with a bandsaw. The charge pipe goes to a 2" to 2.5" steel adapter, then into a 2.5" to 3" silicone coupler from AutoZone. This coupler feeds into my 3" BOV adapter then into the 3" mandrel bend aluminum pipe leading into the engine bay. I brought the 3" down pretty far to try and eliminate turbulence in the MAF.

I am using an STS oil pump to return the oil back to the oil filler neck. I got the pump from an STS dealer who upgraded a customers car to their high volume pump.  I am using the nipple that originally had the vent hose to the intake for the oil return fitting- I am using a vented push in oil cap to make up for it. It was alot easier this way than tapping the oil cap like STS does. Here are the pictures and it you have any questions just ask.

[gofastmerc]

Cool!

Are going to put a shield on the aircleaner? 

When do you get boost?

Butt-dyno?

[Explorer5.0]

Cool!

Are going to put a shield on the aircleaner? 

When do you get boost?

Butt-dyno?

I see boost as early as 1500RPM depending on load. I only have a 3.63psi spring at the moment and see all of that pretty early. As soon as I get some larger injectors it will be going to Bamachips to use their AWD dyno. I am not worried about the air filter because I never drive the truck in foul weather. I am planning on putting a K&N outerwear on just in case- ut will shed water.

[johnsonupnu]

Should suprise a few on the street. 

[bofomills]

The only thing that takes me way from rear mounts, is the rain.. dust your engine I liek your build btw.

[seawalkersee]

What is your boost level now? You running stock injectors and MAF?

Chris

[238ur50]

What is your boost level now? You running stock injectors and MAF?

Chris

 I only have a 3.63psi spring

[Explorer5.0]

What is your boost level now? You running stock injectors and MAF?

Chris

3.63 psi, stock injectors and MAF.

[Explorer5.0]

Here is a picture of the setup before installation. Notice the huge ugly weld where the wastegate pipe meets the exhaust pipe- I had originally planned on the wastegate pipe as being a hanging point so I welded the connection then brazed over it for strength. I forgot to mention above that I did every bit of this install myself- so it is a true DIY.

[Explorer5.0]

I just bought a 6spi spring(small red) for my wastegate, so now I need some larger injectors and fuel pump. I will probably run an '03 Cobra pump with some 30lb injectors if I can find some. I also have the task of getting a MAF that will work blow through. I wish I had the option of putting an FMU on it, but I have a returnless fuel system.

I am also going to AutoZone today to get them to order me a K&N Drycharger so I can drive in the rain if I have to.

[Kevins89notch5.0]

AWD SUV mustan, hahahahaha, thats great.
 

[seawalkersee]

As far as the return oil pump goes, is there a certain location you have to mount it for it to work properly? Like...below the trubo return feed line or doe is matter as long as its within like 18" of the turbo? What are the specifics of that?

Chris

[Explorer5.0]

As far as the return oil pump goes, is there a certain location you have to mount it for it to work properly? Like...below the trubo return feed line or doe is matter as long as its within like 18" of the turbo? What are the specifics of that?

Chris

the pump has a fair amount of suction, but I'd say keep it within 3' and at about the same level as the turbo. I will probably be replacing the pump soon because it makes ALOT of noise. I will probably buy a diaphram pump that will be quieter.

[slo5o]

How much abuse can the stock transfer case in awd explorer take? I have a 99 2 door 4wd that I would like to convert into a 5.0 awd if I can figure out how much the stock transfer case can handle. Nice looking build btw, any track times to see how much of an improvement the 3.63 psi did?

[Explorer5.0]

How much abuse can the stock transfer case in awd explorer take? I have a 99 2 door 4wd that I would like to convert into a 5.0 awd if I can figure out how much the stock transfer case can handle. Nice looking build btw, any track times to see how much of an improvement the 3.63 psi did?

You'll split the block before you make enough power to kill the TC. You can also swap a 4406 out of a full size truck so your 4wd will work as it does now, except you'll have a true 2wd mode.

[dmoss69]

Nice work, and cool build!   

[funford]

nice build, something original.

[95_5.0_stang]

That's awesome, a sleeper right there.  I like the idea of using radiator hose as couplers, it doesn't leak then I take it?  Let me know about that because I might do the same thing when the time comes. 

[slo5o]

You'll split the block before you make enough power to kill the TC. You can also swap a 4406 out of a full size truck so your 4wd will work as it does now, except you'll have a true 2wd mode.

That what I was hoping to hear. How much are you planning to turn yours up to hp wise? And is your trans still all stock?

[Explorer5.0]

That what I was hoping to hear. How much are you planning to turn yours up to hp wise? And is your trans still all stock?

 I dont know what kind of numbers I'll make, but I plan on going up to 6psi soon.

[snake679]

Nice work, and cool build!   

+1

[slickum01]

I have thought of doing this to my expedition for awhile but didnt want to sound stupid with the idea, so I have been collecting different ways to do it, and this helps with ideas.   How does the exhaust noise sound with not having the muffler set up?  Where do you get the vacume from for the wg/blowoff valve, and does the long distance running lines require using a vac can? 
     Thanks

[Explorer5.0]

I have thought of doing this to my expedition for awhile but didnt want to sound stupid with the idea, so I have been collecting different ways to do it, and this helps with ideas.   How does the exhaust noise sound with not having the muffler set up?  Where do you get the vacume from for the wg/blowoff valve, and does the long distance running lines require using a vac can? 
     Thanks

it sounds alot like the exhaust of a modern turbo-diesel with an aftermarket exhaust- half V8 sound/ half jet engine sound. THe BOV is near the front and gets its signal from the brake booster hose; the wastegate sees boost from the turbo charge pipe. I dont use any vac can.

[87-turbo]

looks good

[Explorer5.0]

well I decided it is time to upgrade my turbo. I am not quite sure what I am going with though- I may just upgrade the hotside and leave the coldside as is. I know the compressor is out of its efficiency rance, but it is doing a pretty good job- I just want to make boost come in a little later. I'd like to just upgrade to a higher a/r turbine housing, or a TO4B housing, but finding one hasnt been easy. If I dont go this route, I am going with a T70 with the .84 Ptrim T3 housing, since I already have a T3 flange under the truck.