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410Custom's builds a 2007 Ranger V8 - cu       #: 1712
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 Posted: Mon Apr 11th, 2022 05:32 pm
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"Added by eddie, posted by 410custom "

Engine bay is next up! With her on the lift I can get under the truck or I can put her way down and get over the engine

I need to install the starter, starter wiring harness, along with trans wiring and plumbing
After that I will be putting the engine and exhaust together complete with the Holley computer, efi, wiring and a single wide band 02 sensor
The truck has a refreshed 302 we pulled from a 104k 98 limited. The engine was dressed with all new gaskets and a comp xr cam and springs. The torque monster headers were installed and the long block was dropped into the bay along with the 104k transmission
Then later I removed that trans and used it in a different ranger …. Because we got a fresh built 4r70w with some mild upgrades for this truck from @Brett aka high plains performance transmission.


Recap over back to present day


Teaser pic till I get some pc time



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 Posted: Mon Apr 11th, 2022 05:36 pm
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"Added by eddie, posted by 410custom "




Okay one more
It’s a shame to take the tires back off and put on the lift I could stare at her all day
Two years in bay two…
You can for sure tell she’s like a Kardashian
You can tell she’s “had some work done”



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 Posted: Mon Apr 11th, 2022 05:40 pm
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"Added by eddie, posted by 410custom "
Back at it! truck is now on the lift where much work has been taking place


Had some fun with the floor jack before going up on the lift



Sorry for the messy shop! I was able to clean this up later









First up once she was lifted was to finish the rear axle install.
I had to bend up a new brake hard line for it using a 53" piece of coated 3/8" brake line from Napa
I think it was 53?
Anywho we measured in the store compared the old rusty part to the new lines

Last edited on Mon Apr 11th, 2022 05:40 pm by Eddie Money



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 Posted: Mon Apr 11th, 2022 06:15 pm
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This is major milestone of the build. The suspension fab work has been tacked, welded, primed, painted, and installed!!

If you look at the front suspension while the truck is lifted on the lift you'll notice gobbs of droop or travel. 

410custom has done an awesome job of marrying the superlift, TTD kit, King shocks, and fordpickupman plasma cut brackets, modified torsen bar brace and his fabrication. I couldnt be happier!!! The red calipers are icing on the cake!!!
These pictures and in depth explanations take the build to a whole nother level.  

Sincere thanks 410custom!!

Stick around, more updates coming!!!

Last edited on Mon Apr 11th, 2022 06:20 pm by Eddie Money



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 Posted: Wed Apr 13th, 2022 02:16 am
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"Added by eddie, posted by 410custom"

 Ok, installed the B&M differential cover. 3 coats of red 3 coats of clear....came out sick!











hangtime



new brake line, and rear brake lines installed
Speed sensor wired up, begin install of new E brake cables



diff cover installed with gasket and thin coat of permatex on both sides
Diff and cover were thoroughly cleaned first, of course



rear brakes plumbed and ready to be bled



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 Posted: Wed Apr 13th, 2022 02:26 am
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"Added by eddie, posted by 410custom"

more of the rear axle




new hardline hand bent to shape, I have done this many times it is never easy to get it right (or at least close!)



brake lines mounted with all factory clips / hardware
new E brake cables visible



ooooh la la

Time to switch up focus to the drivetrain
Next parts to be installed are transmission cooler lines, starter, starter wiring harness, transmission wiring harness (customized) converter cover plate and of course we will need some exhaust down pipes.

I setup a bench for doing exhaust, I have this milwaukee band saw just for this, fits nicely in the vise



layout all the pieces and start fabricating
To start I used a few inches of the factory pipes, they give me the bends needed to clear the front diff and get the exhaust routed properly






start cutting the pieces I need, each piece was de burred, chamfered, and sanded smooth for a good fit and good weld prep









many hours later







right where I want the pipes!
Dual 2.5" all the way out
I might incorporate an x pipe to help equalize the banks
Also found perfect spot for the wideband 02 sensor






custom downpipes






all cleaned up



Last edited on Wed Apr 13th, 2022 02:27 am by Eddie Money



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 Posted: Wed Apr 13th, 2022 02:35 am
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"Added by eddie, posted by 410custom"

I am using a 220v mig with c02 / argon it’s a harbor freight multiprocess unit…. But I have not taken the time to learn how to use the tig yet. It is also powered by a generac pos rattle trap of a portable generator. We are off grid so anytime you see me run a 220 welder, plasma, lift, etc it is all run of a portable generac pos rattle trap of a gasoline genset. No need to burden our main battery bank with those heavy loads plus battery banks and welders have been known to not get along

After being off grid for almost 5’years now you learn a lot about generators, generac is not very good lol next time I will get a Honda

This is the first time I have built down pipes from scratch …. I am now addicted to fabricating exhaust! So many years paying shop to cobble things together… now I can finally Re do my own exhaust the way I want it 

We will need to order up two mufflers for this beast. I am a big fan of borla exhaust, but I also love the sound of flowmaster and some others, plus I have had good luck with no name mufflers. I have heard good things about spintech and always wanted to try their design. This is the stage of the muffler selection as of now. We need something slightly compact so I can stuff two of them under here, also I want straight through flow no chambers if I can help it

Last edited on Wed Apr 13th, 2022 02:35 am by Eddie Money



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 Posted: Wed Apr 13th, 2022 02:51 am
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"Added by eddie, posted by 410custom"

I am learning much from this
My welds will improve, for these pipes the tack welds are done in the truck upside down.... have to hold parts, weld, not get burned, etc
Then the final welds were done on a utv tailgate and it had been a long day.....I know I can do better as I get more practice
Sorry Eddie your truck is the Guinea pig! although if these ever fall apart it will give us a good reason to have a visit 

I do plan to wrap the downpipes, I like to use exhaust wrap to push the heat further downstream past the transmission and passenger floorboards

Now that the downpipes are located and mostly sorted out I was able to get back to installing the trans cooler lines, torque converter cover, starter, starter wiring harness and trans wiring harness
Lower trans shield installed! Every little bit counts (sometimes I search for a while just to find the bolts!!)



trans cooler lines, cleaned inside and out, slightly bent to conform to my design
Worked out nicely! I like to use the factory metal lines as opposed to cutting them and running hoses simply because the metal lines do such a good job of dissipating heat, reduce the number of hose clamps, and they are tough




two straight pipes in place to ensure I get the downpipes positioned properly
I am building a few exhaust mounts into the system, first one will be at the trans mount similar to a stock 5.0
you can see cooler lines installed
cooler lines, starter wiring harness installed, do not forget to mount the supports! Hardcore 5.0 dudes will notice for my purpose here I haver moved the trans support bracket to the same bolt as the wiring harness support bracket



That is the underside of the pass engine mount plate
cooler lines in place!



104K starter and starter wiring cleaned and installed. All terminals cleaned and treated with anti corrosion spray


can see the lower trans shield from before is also in, over to the right is our red urethane front diff bushing




another shot of the wiring and cooler line supports, proper routing



the starter / charging harness is mounted to the front of the 5.0 here with these two brackets



transmission cooler lines are wrapped with some heat shield material when in proximity to the exhaust. Remember exhaust downpipes will be wrapped also




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 Posted: Sun Apr 17th, 2022 04:27 pm
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"Added by eddie, posted by 410custom"

Now time to start the wiring for this rig

It all begins at the starter, alternator, ac and low oil level harness from the 98 5.0 104K donor
harness is cleaned and repaired before install


I can use this harness as it is, no mods needed

typical repair of the factory wrap



transmission / 02 sensor harness is getting cleaned up, this dude will need some mods for our build



FYI the wiring harness are the dirtiest part of a build! much time is spent wiping them down so I can work with them

So when Brett built our 4r70w we make sure to use the 98-01 style bulk head wiring connector along with its corresponding internal hard wiring harness and 98-01 style solenoids
Half way through 97 the 4r70w changed from 9 wires to 7. I needed to make sure I had the correct harness/bulkhead fitting before plugging it in



7 wires we have the correct harness, no mods needed
I keep this chart (along with many others) pinned to the wall in the shop because I am often making changes to these transmissions



Now inside the 5.0 transmission harness is also 3 of the 02 sensors. This truck will be using a single wideband 02 sensor with the Holley drivetrain computer....so I removed two of the 02 sensors and their wiring. I will route the bosch 02 sensor to the holley computer using the factory wires and blue plug




time to unpin the removed wires, harness is cut down and 2ea 02 sensors go bye bye






Harness will be re wrapped and installed along with the transmission case vent



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 Posted: Sun Apr 17th, 2022 04:29 pm
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"Added by eddie, posted by 410custom"

Guess what

The Holley system INCLUDES the transmission plugs as well as wiring to the 02 sensor… no splicing into the factory harness.
I am reading the instructions…..
Again

So no need to mod the factory trans harness
Forget all that stuff I posted this am about that
Whoops… stupid human brain fart (goes to remove factory trans harness from truck)
Battle on

Last edited on Sun Apr 17th, 2022 04:30 pm by Eddie Money



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 Posted: Sun Apr 17th, 2022 04:33 pm
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" Added by eddie, posted by 410custom "

Phew okay

Sorry for the trans harness debacle I got on a roll.. I always dig out and stage the next set of parts to be installed the trans harness was just begging to be cut up and Re wrapped. Now I basically destroyed a perfectly good 98 5.0 trans harness lol lol

We spent much time yesterday researching mufflers enough to make my head spin. I learned hooker exhaust is actually Holley very interesting, they have a very nice active exhaust system which is way out of our budget. Also been looking at vertex mufflers which are tunable electronically… sweet but $350 each plus $350 for the controller plus plus plus stuff is wicked cool but can get expensive and complex real quick! I researched crossovers and cutouts as well

I ended up ordering a 2.5” x pipe we will be incorporating instead of an h pipe like I had planned. X pipe is for sure the way to go and a crossover is a very good idea in a system like this it improves power and torque and it lowers the decibels a bit.
I am still researching mufflers but again I am leaning towards to basic Borla single in single out units. Once the truck is running and in service and proves itself (like a good 5.0 ranger) then we can come back and do electronic cutouts or electronic mufflers etx… right now that $$$ and time is needed for shocks, wheels, tires, fuel system, etc etx

I read and Re read the. Entire Holley terminator manual…. Way too easy! Seriously. I am holding my tongue right now but that Holley system makes it way easy to get this 5.0 and 4r70w up and running

Wire in the factory mas, tps, crank sensor, cam synchronizer, injectors, and a few other things really very straight forward. I have the coil pack drivers needed to run the stock 5.0 dis for now that is the way we are headed. Running 8ea ls coils and converting to a cop engine sounds fun too, but i have this system here so that’s what this truck is getting.

I have already attached the Holley transmission wiring harness and routed it up the spine of the trans. I need to order a line pressure sensor from Holley this will allow us to monitor trans line pressure, a nice option from Holley wiring is included

I also built the Downpipes exhaudt support from the factory 5.0 bits. Once I finish this work up today I am lowering the truck down so o can put the engine together. I have some hurdles to overcome like fuel system plumbing / regulation otherwise I see no reason I can’t have the engine together, wired, the Holley pcm mounted and ready to begin the programming process very very soon

Yes I am using the factory 98 5.0 starter/alternator/ac harness it includes all battery power wires, engine and chassis ground, alternator charging circuit, ac compressor clutch wires and low oil level pan sensor wires. No mods made to that harness.
Yes it is totally possible to
Build your own starter harness, battery cables, alternator harness from scratch, I have done that many times too
98 explorer has two starter relays one is in the power junction box and the other is of course built into the starter itself.

Last edited on Sun Apr 17th, 2022 04:34 pm by Eddie Money



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 Posted: Sun Apr 17th, 2022 04:40 pm
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"Added by eddie, posted by 410custom"

Exhaust downpipe supports built to sit in the factory 5.0 hanger





Parts removed and ready for final welding
Holley provided 02 sensor wiy bung also in place, requires drilling a 7/8” hole

Holley provided bung



5.0 exhaust hanger in place
You can also see the Holley transmission wiring harness has been installed

Here is the harness as shipped











There are several loose wires included with the holley, reverse trigger, od on off, and others
You can also see the included harness for the optimal transmission line pressure transducer which I plan to add to our 4r70w





I thought it was interesting that all 10 pins are populated in the 4r70w connector, this is the 98-01 4r70w harness




Interesting, during setup we will be telling the new computer what trans we have so I assume this works with both 92-97 versions of the 4r as well as our 98-01
Style solenoids
Hard to wrap your head around when you are the guy always moving these pins around and deleting power feeds? How can the Holley computer move battery power from one wire to a different one and replace it with the solenoid trigger wire?? It maybe that the wiring changes for our 98-01 specific model happen upstream and they just leave all 10 pins in place.
Yes I have a tendency to over think things.

More on the “loose wires” in the 4r70w Holley harness









Compared to the wiring I normally have to do for a v6 to v8 conversion this is a breath of fresh air. Getting the 07 truck can bus system to be happy with it is another story since the 07 sohc pcm was part of the system. More on that later as we get deeper into this
This Holley system would be perfect for say a 1988 bronco ii that was going 5.0 lol lol 20 years later!!



The Holley harness includes connectors for both types of 4r70w oss sensors just fyi




Holley wiring harness is very high quality



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 Posted: Sun Apr 17th, 2022 04:43 pm
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"Added by eddie, posted by 410custom"

Now more on the exhaust pipes and how they fit a ranger I have them tucked up higher then the frame rails and there is a ton of room in here compared to a stock 5.0 system, very good for keeping the trans cool!


02 sensor mounting info from holley
Basically within 10-12” of the header collector on one bank and mount it so no moisture can hit the tip


I picked a nice spot where the wires can reach easily, plenty of room for 02 sensor socket, and it’s tucked up where it won’t get sprayed by road grime or hit by rocks, also does not impede your access to other fasteners

Whew a lot goes into these simple things when you type it out








I left these bends in place in case the superlift is ever removed it should still clear the front pinion. Why would you ever? Who knows, these trucks can be on the road for 20-30 years you never know what will happen….







More pics of starter area







Lots of space for a larger/taller setup on pass side






Here is where the dual 2.25” pipes are headed on the ranger i take one over and one in the factory spot of the crossmember


 



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 Posted: Sun Apr 17th, 2022 04:56 pm
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"Added by eddie, posted by 410custom"

The terminator x also has a built in map sensor you can use if you don’t want to source a 3 bar one


I just lowered the truck down on the lift = the exhaust is done for now

Next I can assemble the engine bay
The Holley will be going in now

Read the quick start guide it is very helpful

Exhaust pipes were removed one more time for final welding



cleaned up and re installed, x pipe will go in when it gets here



first the passenger side pipe, slides into the 5.0 factory hanger assembly



followed by the drivers side, slides into the lower spot of the same hanger, from the other side





The drivers pipe support also includes the first clamp, which will allow this exhaust to come out in 3 sections



The little heat guard on the side of the 4r70w that protects wiring harness was slightly bent to clear new support







tons of airspace between trans and new downpipes!



time to install the Bosch wideband






pipes tucked up nice and tight



pretty






some final shots before I lower the truck






4406e clearance in a ranger using my crossmember/mount



and she's down!



Next up lets complete the 5.0

Last edited on Sun Apr 17th, 2022 05:04 pm by Eddie Money



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"Added by eddie, posted by 410custom "

Lying on a creeper checking it all out


The exhaust pipes were in and out of the truck about 15 times while fabricating

I have an special 19mm swivel socket on 3/8” drive extensions with Milwaukee 12v powered ratchet that makes short work of getting them in and out, but Patience is needed for this sort of work to get everything placed where it won’t bang around, won’t melt anything, won’t heat up the floorboards or boil the atf. A good mechanic has much much patience and working over your head all day on your feet…. Well you could say I sleep good at night during the spring time!

Now I will be cleaning, detailing, modifying and installing 302 parts for a while time to get out the soldering iron!



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"Added by eddie, posted by 410custom "

You ready for an update? Lets do this. Few pictures to get through

Some of this maybe boring........... unless you are installing, thinking of installing, or even just wondering how you install, a Holley Terminator in your RBV, 
In that case this will be very interesting, just like it was to me!

First up, the magnaflow 2.25" X pipe arrived, what a neat piece this is, perfect spread for our twin 5.0 pipes


Yes those are new Beltech Chevy rear 1" lift shackles, these will actually give the rear of this truck a .5" lift at the axle.....this truck needs them...........more on that later

after much deliberation and checking the perfect location for the crossover pipe was chosen



slipped right in place just after the transmission crossmember






Now I was able to measure and mock up a set of imaginary mufflers
Which lead me to actually ordering two mufflers....I settled with Spintec 3000 series 2.25" low inlet and 2.5" centered outlets.....
This thing is going to sound sooooooo good



They are nice and compact (4x8x13.5), I love the spintec design, I have heard good things........I have wanted to try one of these mufflers behind a 5.0 for some time and now we are going to try two 
I know Eddie Money will approve...cammed 302 tuned and run through this exhaust? I can't wait!



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"Added by eddie, posted by 410custom "

Now for the Holley install, this thing is so sweet, once you see what is possible with this Holley system for these conversions it is easy to justify the $$$ spent. The wiring is simplified BIG TIME if you want to convert a v6 truck to the Ford gt40/4r70w setup

That does not mean there is not some wiring, because there is.
And there is a complex installation happening here, but the end result is going to be oh so sweet. I am now saving my pennies so I can put one of these in my daily driven Bronco, and one in my upcoming Sport Trac project too.....

The Holley EFI terminator PCM and harness kit we got for this truck starts right here



This is the main harness (558-104).
This connects our drivetrain/truck to the Holley PCM
There are also sub harness that connect the truck and more drivetrain to the Holley main harness and thus PCM
These include:
Power harness
Injector harness
Transmission harness (4r70w)
Input and output harness
 (for controlling e fans, ac, more)
Ignition input harness (558-304) (in our case this has leads for a CPS camshaft position sensor and CSS crankshaft position sensor)

Ignition output harness and then there are several various ignition harness' available from Holley.
This is where the majority of the wiring will take place depending on which ignition system you decide to control. We are going to stick with the factory Explorer EDIS waste spark ignition and the Ford coil packs.
To do this with the Holley you will need an ignition harness to connect the Holley PCM and some coil drivers to handle the two coil packs.
Our ignition is waste spark, which means it actually fires two cylinders at a time, one spark is simply wasted on a cylinder that is on exhaust stroke, wasted.

Holley does not make a plug and play ford EDIS coil pack ignition harness, instead we have to build it ourselves. This is true for many of the ignitions the Holley is capable of controlling. To run a coil near plug ignition is also very possible with the Holley.
When our kit was purchased many of the options they have now did not exist, but that is okay.. we are not afraid to do some wiring here.

For the ignition I am using a universal coil on plug harness (558-307) from Holley that plugs the terminator PCM into our 4 channel coil drivers (554-123) and then will be wired into the stock coil packs. This took a little bit to sort out, but has been done now, I even made a map in Autocad.

This is the PCM side of the main harness, you can also see the main power harness (coiled up) and I am holding the small plug where the Holley handheld 3.5" controller plugs in.



This is the ignition adapter harness for HEI ignitions, (ignition signals in) it includes connections for a 3 wire CPS and crank sensor. I had ordered a motorcraft 2 wire cam synchro (98-01 5.0) but during my research I would learn that other Holley efi users have a difficult time getting a reliable signal from the 2 wire. As a result I ended up ordering a 3 wire cam synchronizer and sensor…(96-97.5 5.0)



Here is the inputs and outputs accessory harness



main harness connections for various engine sensors listed below, on top n the pic the WB02 lead


I will cut these ends off and solder in the factory ford connectors

Here are the 4 channel coil drivers needed to run the ford coil packs


Again I will be removing many of these plugs and simply soldering the wires, making a tailored to fit streamlined drivetrain harness.


The Holley main harness (558-104) in addition to the sub harness above, will have connections to:
CTS (coolant temp sensor, PCM)
WB02 (bosch wideband 02 sensor)
Fuel Pressure Monitor (I ordered a transducer for this to add to our fuel rail)
Oil pressure monitor (ordered transducer to add to 5.0)
MAT (manifold air temp, for us Ford dudes this is the IAT intake air temp sensor)
Knock sensor (optional, we are not going to add one)
MAP (the terminator PCM has an internal MAP sensor that will work for non boosted setups) We may or may not add a separate map sensor depending on plumbing to the PCM
TPS (throttle position sensor, stock 98 explorer)
IAC (idle air control valve, stock 98 explorer)

Stock Explorer 5.0 systems that we will be deleting:
MAS
, no more mass air flow sensor to plumb in
EGR, no more EGR system, a simple block off will be fabricated at the intake and passenger header
Canister purge and canister vent solenoids (I am working on adding separate holley module that can control a simple canister purge solenoid. I like to retain the stock charcoal canister and use a purge valve to burn off EVAP emissions into the intake just like the stock systems do)

Loose wires
Included in the main harness are several inputs and outputs, like for controlling AC WOT relay, electric cooling fans.
There are also two CAN BUS wires, I am not sure what these are capable of talking to or from just yet. aside from communicating with the Holley handheld or Smartdash (yes please!)
The transmission harness has wires for OverDrive on and off controls, NSS Neutral safety output (good for E shift t cases), and reverse light trigger.
Other loose wires are for power connections, fuel pump control, and some ignition stuff we do not need.

On my PC now are many Holley wiring diagrams and instruction pages. I have spent much time researching, plugging in and stretching, identifying and getting myself familiar with every single wire, until I was ready to finally begin the actual installation of the equipment.

I have been putting together Autocad drawn diagrams/Maps of the Holley wiring that will be going into this truck, once they are confirmed they will be posted.



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2007 Sport 4door 4x4 4.0L SOHC V6 Ranger
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 Posted: Wed Apr 27th, 2022 12:49 am
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"Added by eddie, posted by 410custom "

Some delays! Holley ignition harness came in

So did the Spintech mufflers

Wiring is happening now



These mufflers are built very stout! Compared to most this size, these are way beefy!!
Here is a look inside the inlet, you can see the path the exhaust takes into the "spin" chambers



And from the outlet, how the exhaust exits the chambers



unfortunately, I had to wait for the Holley ignition harness to get here
I am using coil on plug universal harness





This harness plugs into the coil drivers the other side comes with pins on the wires, and this will get pinned into the existing PCM connector


So now I was able to lay out the entire Holley system! Please note the transmission harness and wideband 02 sensor were already in the truck, so not pictured.



you can see bottom right, this is one of the two transducers I purchased on Amazon, one is for transmission line pressure and the other is for fuel pressure. Both will get plumbed into the truck and give us info on the Holley 3.5" screen interface.
The black "PCM" will get mounted in the center console (or under pass seat), the main wiring will run through the floor plate and up the spine of the transmission

The new ignition harness is pictured plugged into the coil drivers, ignition wires for our Ford coil pack setup will get pinned into the pcm
up close



ignition side of things



fuel injection harness, connectors are for 96-97 style injectors, I changed these over to EV46 connectors for our 98-01 "returnless style" 19# 5.0 injectors




the rest of the drivetrain connections



on the right is our GM HEI ignition input harness, this hooks to the stock 5.0 THREE WIRE (3) CAM POS SENSOR (do not use the 2 wire) and the stock 5.0 crank sensor

Above it are connections for oil pressure, IAT (intake air temp), MAP (3 bar map sensor, unless you use the one built into the PCM), IAC (idle air control), TPS, knock sensor (not using), fuel pressure, and coolant temp sensor (CTS, for the computer)

I hit up the junk yard to get factory pigtails, this way I did not have to hack up one of my harness since some connectors are 96-97 and some are 98-01. I nabbed several connectors off of a v6, no difference
'
This system is now going in the truck, stay tuned.



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2007 Sport 4door 4x4 4.0L SOHC V6 Ranger
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"Added by eddie, posted by 410custom "

Oh yeah.... I almost forgot........ the most important part


This is the chart I built in AutoCAD showing the Holley Terminator X to Ford DIS coil pack ignition




I took pictures directly from each Holley component installation manual as well as my trusty Ford wiring book and inserted them directly into the cad file. Then I drew a simple chart so we can make sure to have a perfect understanding of each circuit and each wire.

THIS HAS NOT BEEN TESTED YET
I take no responsibility for you wiring up your project
I am simply sharing with you guys my build and how this all plays out.

With that said, the wiring shown is very straight forward (no guesswork involved) thus I expect this to be how the truck gets wired final



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2007 Sport 4door 4x4 4.0L SOHC V6 Ranger
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With all that wiring, which many probably just stare at the situation at hand.  We waiting for the next post where the hands are thrown in the air and you tell everyone due to current laws and "climate change" social pressures, the Tesla swap is now on the way.. lol

jk



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My tow rig is a Prius to offset my carbon foot print... 



Lol. Joking...



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2007 Sport 4door 4x4 4.0L SOHC V6 Ranger
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Seems Legit.. I've seen crazier



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