I am about to inherit a 1997 Mercury Mountaineer AWD 5.0 from my father who is going new, and handing this down to me. He's had it since new, and it's in pristine condition aside from a couple parking lot dings.

Now, I have a 1993 Bronco which is my Off-Roadin' Machine, and Towing. So, the Mountaineer won't see much (if any) towing or off-road duty. So, I figured I'll go the opposite direction with it. On-Road Performance. I figured with the 5.0L engine being one heck of a popular engine, and the Mountaineer/Explorer being one heck of a popular car, High Performance upgrades shouldn't be hard to come by. But, it looks like the 5.0L was only used in these rigs for a very short time, and not exactly the most popular model.

I'm having a hard time finding bolt-on upgrades for it. I'm not looking to go super-powered, but I'd like to upgrade the exhaust, intake, computer controls, ignition, and suspension. I found a custom made Cold-Air Intake on eBay for it, and that might get ordered. But, I would like upgrade the exhaust. I bought a Flowmaster Cat-Back kit for another car, and was very surprised with the sound and performance increase compared to the custom setup that was previously on the vehicle. But, I couldn't find a kit for the 97 5.0 Mountianeer, so looks like a Custom Setup is in order.

Anyway, Any advice on where to look for How-tos, or where to shop, or how to proceed would be really appreciated.

 

there is a webiste/company called explorer express, best bet is to check there

 

Thanks.
I've been looking at thier products. I was hoping there might be another vendor someone could suggest also. I found a set of Mustang Clone 16 inch rims that I'm considering for wheel upgrades, but wheels for Explorers/Mountaineers don't seem to be in short supply.
Engine Power upgrades still seem to be.

I'm considering redoing the exhaust almost from scratch. Downsizing to 2 Cats, and maybe trying a Custom Dual Setup, but I've heard that is troublesome, so it might just come to a 3 inch mandrel-bent single system with a Flowmaster 40 Series Delta Flow.

Anyone have any issues using only 2 Catalytic Converters? Like of the legal Emission variety? Or of the O2 Sensor type either? Any Hi-Flow Cats anyone can suggest?

 

'Most' Mustang 5.0 parts will work, but there are certain ones that will not fit. Best way to start this is to know a price range you are looking at and just how much performance you want. A couple of things I would suggest starting with are:

-Mac intake
-Torque Monster Headers (one of the best things you can do.)
-Exhaust

I would recommend the TM headers over just about anything. One of the biggest problems with the Explorer 5.0 set up is the restriction on the exhaust. These are by far the best headers on the market for our rides. Your thoughts on exhaust are good also. There are a couple of catback systems made, but I would remove the two front cats - leave the O2 sensors in their spots, and go with either a 3" single with either a Magnaflow or Flowmaster 50 Series Delta - or a dual system with the same 2 cat set up. I removed all 4 of my cats years ago and replaced them with 2 Magnaflow hi flow cats and have not had the first problem. I am running the 3" single right now, but am in the process of building a dual set up with an x-pipe (my neighbor is a welder and is helping me). The problem with a dual set up is running dual pipes. The only safe way to do it is to drop the spare tire.

Other than those 3 things and then maybe a SCT XCal2 tuner, you pretty much start getting into internal mods like a good cam, rockers, heads, etc. Your X has a good throttle body (65mm), good upper and lower intake (GT-40 setup), and a 70mm stock MAS. Upgrading any of those will not really gain any noticeable performance without changing cams and maybe heads.

Now, if you do get into that far, then I would recommend going to maybe 24lb injectors, an adjustable fuel pressure regulator, and maybe a MSD DIS4 ignition. Unless you start doing internals, the stock fuel system and ignition is more than enough.

 

Thanks for the tips on the Headers. Will they match up the stock exhaust pipes?
Eventually I'll fabricate all new pipes to match up the headers, but I won't be doing it all at once.
Any installation tips for them?
That 5.0 seems to be shoehorned into the Mountaineer (at least compared to my Bronco), so I'm guessing there are some tricks to get the manifolds out, and the headers in.

I'm really looking forward to squeezing some performance out of this truck. My dad wanted to perform much of the upgrades I'm planning. He was unsuccessful in finding parts for it. He considered an engine rebuild (he and I are no stranger to engine build ups, we used to Drag Race) but he was not comfortable ripping out a perfectly good engine just to blast ricer-boys at stop lights. I am not comfortable with that either.... yet. When the time comes for an engine rebuild, I'll do Port/Polish heads, upgraded cam, and a new engine management computer.

Until then, I'll try bolt ons. The DIS4 System is something I've always wanted to try, but was hesitant with all the possible computer issues. And now that Delaware DMV plugs into ODBCII Connector to check for errors, I really worry about inspection issues with it. Have you used a DIS4 with the 5.0?
What kind of performance increase could I expect? Any issues with use?

 

The 5.0 is shoehorned into an X. It can be a PITA to work on at times...

The TM's come with great install instructions. Took me about 4 hours to do them, but it takes most first timers about a day (or even a weekend for non-gearheads). They bolt straight up to the stock pipe placements, so they can be used with stock exhaust setups. Call them and talk to Bob. He is a great guy to talk to and is more than happy to talk shop. They run almost $700 a set, but they are worth it. The only other option available is the FMS headers and they run around $350, but they are not hardly any better than stocks. The TM's are larger and have a group collector, plus they come ceramic coated. By the time you bought FMS's and had them cermic coated, you would be close to the TM price and still not have half the performnace of the TM's. (I know this sounds like an ad for them, but they are that good - one of the best mods you can do.)

I run the MSD DIS4 on my X now. It was an easy install and does not mess with a stock computer. But to get the most out of it, you would need to run a tuner. On a stock 5.0 with nothing else major done, you won't see many gains - not for the price tag. You have tobuy the DIS4 box and 2 tach adapters to go with it to work on the Explorer. That will bring you to around $450 for them and the gains are just not there unles you are pouring more air and fuel in to need the extra spark. I am running a ported/polished Eaton M90 supercharger with 7lb pulley along with 36lb injectors, adj fpr, and a fuel pump out of a Lightning, so I needed the additional spark.

For the money, an intake, the headers and exhaust, and a tuner are the best mods for the money to start with. That will net you your best bang for the buck to start with. Then you have to get into the internals to pick up anymore. Larger MAS, a larger throttle body, the MSD ,etc, just won't show anything unless the first three are done.

 

Cobra,

Did you lower your Explorer at all? It looks a little lower in the pictures. Maybe that's the Rims giving that effect though.

What is your opinion on lowering these trucks? I'm not thinking about anything drastic, just a couple inches.

It seems you have much the same tastes as I with your ride. Much of what I've seen you've done, I'd have done in your situation. Except I prefer a darker color. What I have in mind to do to my truck might just make my Mountaineer, the Evil Twin to your Explorer. That is provided I can get the funds to do it.

 

Yes, I have mine lowered roughly 2.5" all the way around. Torsion twist up front with Steeda 2.5" blocks in the rear. As with all lowered rides, it does ride a little rougher, but nothing like a slammed minitruck. As far as suspension mods go I would definitely recommend getting the Explorer Express sway bar kit. It makes a very significant difference. I would also go with Bilstein shocks. I have tested about 10 different makes/omdels of shocks on the X, and the Bilsteins out perform all of them.

I am finally getting my X to the point I really want it. I've spent the last 10 years basically testing parts... lol... I have changed them so many times. When I had my X painted, I really wanted to change to the charcoal gray, but because of time restraints, I left it white so I wouldn't have to pull the engine and door frames, etc. I do love the white though. Just has a clean look. But I do like the gray and was going to add silver or light gray gost flames on the front...

 

When you say Torsion Twist, you mean twisting the Torsion Bar right?
I'm not terribly sure I'm up to doing that on an AWD truck. What do you think about the Explorer Express Lowering Kit? Obviously I won't get as low as you, but do you think it's a safer bet for an All Wheel Drive Truck?

It comes with Shocks, but maybe the Bilstens you mentioned might be a better deal. What are the model and part numbers for our trucks? Do you have a link to a vendor page for pricing and appilcation checking?

I was thinking about KYB Shocks. You tried them yet?

And I'll be upgrading to 16 Rims at some point for handling upgrades Also. I don't feel ready to go to 17 or larger. Scratch that, my checkbook isn't ready for that. I noticed on tire rack that 255/65/r16 are listed as an optional size for the Explorer/Mountaineer. Do you think a 16x8 rim can accomodate a 255/65R16 tire? I'm thinking about these Kuhmo ECSTA tires for my Mountaineer. I've used Kuhmo Mud Tires in the past and was satisfied with the wear and performance, and they are a really good price.

I figure with a slight lowering and the tire/wheel upgrade it should handle much better.

 

Even if you buy the EE kit, you have to do a torsion twist. Doing a torsion twist is simple - you jack up the front of the X and find the 9/16" bolt at the back of the torsion bar. Loosen it to lower the ride height, tighten it to raise it. You do not actually twist the torsion bar itself. After you do it, you must have an alignment. That goes with any suspension height changing mods though...

The EE kit is OK, but for what comes in it, you can do a lot better with the money. It comes with Edelbrock shocks which are terrible. I would just buy the sway bars from them and out the rest of the money into Energy Suspension bushings and Bilsteins.

I have run the KYB's and know some others that are still running them, but most tend to like the Bilsteins the best. I don't remember exactly, but I think http://www.shockwarehouse.com/ had the best prices on the Bilsteins, plus they have free shipping.

Me personally, I would save up a little and either get 17" or 18" wheels/tires instead of 16". I would hate to see you put almost a $1,000 in them and then not be as happy in a month or so. My personal choice is 18" running 255/55/18's. I also have a set of 17" '95 Cobra R's that I run 255/60/17's on. I don't think you would have a problem with a 255/65/16 tire on that wheel, but for the look and stance you want, I don't think it will look at good. JMO of course...

I don't know much about the Kuhmo's. Maybe someone else has run them and can offer something better on them. I am running the Michelin Cross Terrains on my 17's and Hankook Ventus ST RH06 on my 18's. The Hankooks are strictly performance tires and are not too good in the snow, but they have done great in the summer and rain. The Cross Terrains are great no matter what I do to them. Long lastly rubber and does great in the snow...

 

As far as 17" or 18" wheels, It's not the wheels I dread paying for. It's the tires. I go through tires pretty quickly on my performance machines, and 17/18 inch tires are still to expensive to replace every year (or more).

I looked up the Bilstiens on shockwarehouse.com and they are a decent price. I think I will go for them. They are only about $60-80 more than the KYBs I was looking at.

I think so far, my list of mods goes like this.

#1 - CAI
#2 - New Black Trim Headlights/corner lights/turn signals
#3 - Bilstien Shocks
#4 - Wheels & Tires
#5 - Sway Bars (Front & Rear)
#6 - Headers
#7 - Tuner
#8 - Lowering Kit

I put the wheels and tires lower on the list, because the Stock Wheels and present tires are not performance, but they are good in the winter. So the new tires can wait till spring. But, the light housings are already yellowing, so they need to be changed very soon. The shocks are an easy replacement and a decent price so they come pretty soon on the list.

And as far as Alignment with the lowering. That's not a problem. I work for a Dealership Chain that has 4 Ford Brand Dealerships and many Service Centers that I get discounts at. Speaking of, If you need any parts, for a cheap price, let me know.

 

Sounds like a plan to me...

Only thing I would change it moving the sway bars to the top. You will be very surpised how different the Explorer reacts to them over stock. Even with the same amount of power, most say it feels stronger and mroe stable because of them.