> I am contemplating, no, make it I need to replace my engine in my 69 car.
> As some of you know, it had a Boss 302 transplanted into it years ago by a
> previous owner.
Steve Liebenow faced the same issue. He had a way overbuilt Boss 302 in a
Mangusta. The jackshaft had been changed and he wanted to keep the canted
valve Boss 302 short block (turned out to have a Trans Am bottom end with
the special rods and crank) so I put together a combo using a set of Aussie
2V heads, a B&A Street Boss 302 intake and a Comp 270 cam. He seemed to
like it quite a lot. Anyway, the Street Boss is similar in height to the
Performer RPM.
BTW, I keep meaning to join PI but my procrastination knows no bounds.
I'll try to call Monday to join.
> Block: Mexican 302 bottom end, OR, a 5.0 roller cammed motor. I've heard
> that the 93ish motors had forged pistons and that the blocks have a higher
> nodular metal content for strength. I figure my top RPM's will be in the
> 6500 range.
For what you are doing, get a 5.0L roller cam short block but balance the
crank to 28.2 oz-in from the 50 oz-in factory balance factor. The 5.0L HO's
are a durable engine but the balance factor can cause the crank to crank
if you spend much time above 6000 RPM. Used to happen to the American Sedan
5.0L's. It only takes a bit of mallory metal so the cost isn't bad to get it
to 28.2 oz-in and the crank will live. This requires a matching harmonic
balancer and a matching flywheel. The 5.0L HO flywheels are 157 teeth and
your Mangusta is likely 164. It can be used or you can switch to an aluminum
flywheel for some zip. You don't want to internal balance unless you are over
7K RPM most of the time.
The late 5.0L blocks are a harder metal and wear better. I've attached a
post detailing what I found when I pulled my 5.0L HO apart at 163,000 hard
miles but it was amazing. Zero bore wear. Very good block up to around
400 HP at the tires. If you turn high RPM, the failure mode is main cap
walk (caps fretting against the bock). The 5.0L Kewl Dudez will split the
block down the center or spit the crank out the botom if they run too much
boost or nitrous.
I really like hydraulic roller cams but there are some things you need
to pay attention to if you want them to pull to 6500 RPM.
Be aware that even among H.O. engines, there were a lot of variations from
year-to-year. Compared to a standard passenger car 5.0L, my 1987 H.O.
has these differences:
forged flat top pistons (pistons are usually slightly above deck at TDC
to maximize quench, the compressed gasket provides required piston to
head clearance)
double roller timing chain
metric low tension oil rings
double sump pan with low oil level sensor
chrome plated valves
hotter roller cam with 0.440" lift
351W firing order
E7TE "truck" heads
60mm throttle body
intake manifold with larger ports (both upper and lower)
different EFI computer
cast aluminum valve covers (will work with roller rockers if
filler neck baffle removed)
true dual exhaust
different brackets and accessory locations
Certain HO's had forged pistons but the '93's had hypereutectic which
aren't as durable. I'll make a separate post with the detail changes
over the years. The Explorer motors had a short nose water pump and
front dress that might come in handy.
> Aluminum Ford Motorsports version with 1.90" and 1.6" valve sizes.
Those aluminum GT40's are an okay head for the money but for around $300
more, the AFR 165's are quite a lot better head for what you want to do.
> Roller rockers.
If you keep the spring pressure reasonable, the bolt down roller rockers
work just fine and are inexpensive. You shim them once and forget. Never
have to worry about the poly locks backing off. Ford used the 1.72:1
Crane bolt-downs in the '93 Mustang Cobra and the Scorpions are nice too.
I have the Cranes. The Boss 302 windage tray is nice to have.
> Have any of you installed the Edelbrock Performer RPM manifold
An even better intake is the Ford C90X FoMoCo intake. It was designed
by Ford and marketed through the Muscle Parts program for the 351W
head conversion package. Alex Denysenko holds IHRA and NHRA national
records with his 289 and 5.0L Mustangs and has done extensive dyno
testing on the SBF. Based upon his dyno and drag testing, Alex ranks
the high rise SBF dual plane intakes as:
Best: FoMoCo C90X
Good: Edelbrock Air Gap, Edelbrock Performer RPM, FoMoCo Shelby
lettered, FoMoCo Cobra lettered
Fair: Edelbrock F4B
Poor: Weiand Stealth, Colt 65
He also lumps the single plane Weiand Xcelerator and Torker 289 in
the poor category, along with the Offy Dual Port, Offy 360. He rates
the Victor Jr. as the best horsepower intake and the C90X as the most
flexible. Super Ford magazine did a SBF intake manifold flow comparison
test in the early '80's. Jim Miller of JME did the test and the 5 intakes
tested were all provided by Alex. They included an Offy Port-o-Sonic,
a C90X FoMoCo, a Shelby Ram Box, an Edelbrock Toker 289, and an Offy
Dial-a-Flow. The Torker 289 was the worst performer of the group.
Second best was the FoMoCo C90X surprisingly. Alex claims the C90X
still bests the latest Edelbrock Air Gap Performer RPM in making power
over a wide RPM range. As far as low profile intakes go, he rates the
factory cast iron 289 4V intake as decent to 5500 RPM on a 289/302
with a litle match porting and puts the Edelbrock Performer in the same
category. Be aware there were several versions of the C90X (including
repros). If you're interested I can tell you how to check the intakes
to know if it is a real one or not.
> what difficulties did you have with the jackshaft and are there any
> clearance issues with the stock shields/covers ???????
Do you know Steve Liebenow? You might want to pass this question by him.
> found a crack in one of the exhaust headers. I also need new mufflers,
I'm not sure if you followed the discussion in the engine forum but
there's a lot to be lost or gained in mufflers and headers with the
SBF, particualry with good cylinder heads.
Dan Jones
P.S. Here are a couple of posts that might be relevent:
Over the Christmas holiday, I pulled the 5.0L HO out of my 1987 Mustang GT.
The engine had 163,000+ hard miles and still ran fine, held good oil
pressure, and got good gas mileage but I figured it was time for a look-see
inside.
The Mustang is my daily driver and by "hard miles" I mean everything from
driving the car for extended periods at triple digit speeds (e.g. ran a
full tank with the cruise control set on 105 MPH), using it like a truck
(hauled two complete 351C's in the back from San Francisco to St. Louis
running most of the time at 90 MPH), winter driving, daily short trips
where the engine never warms up, daily bursts to yellow line, etc. In
my defense, I do allow the water temperature to stabilize before hammering
the throttle. I also do regular oil changes and whatever maintenance is
necessary. For the first 40K miles, I ran conventional oil changed at
3000 miles, after that I switched to synthetic oil (primarily Mobil 1 but
also Castrol Syntec) changed every 5000 miles.
The Mustang is the first and only car I've owned since new, so I was
curious to see what it looked like inside. Previous to the Mustang, I
had a 1979 Buick Regal as a daily driver that was purchased with 70K
miles showing on the odometer. When I opened it up, it was evident the
previous owner didn't change the oil on a regular basis. The oil pickup
screen was completely clogged (only the bypass hole was pulling oil in),
the bearings were in bad shape, the timing chain was flapping in the
wind, and there was carbon build up everywhere. My Mustang's 5.0L HO
was at the opposite end of the spectrum. The inside of the engine was
completely clean. When we ran the rifle cleaners through the oil passages,
they came out as clean as they went in. The only build up was a slight
amount on the tops of the pistons and the exhaust valves. The block showed
no wear whatsoever: no ridge and the original honing cross hatch marks were
still visible. The valves and crank were still within the tolerances for
new parts. The roller cam and lifters were fine. The cam bearings were
like new, in fact they were a bit on the tight side. Even the connecting
rod big ends were still round.
I had heard the nodular iron 5.0L blocks wore quite well but I was
surprised to see how nice the engine looked inside. I was expecting
some wear due to the fact I was running a K&N filter which probably
does not filter as well as a paper filter. Also, I spent a year in
the Mojave desert and upon my return, noticed the air inlet tube had
a gap at the bottom that allowed unfiltered air in. In all his 60+
years of engine building, my dad had never seen anything look so good,
especially given the hard usage. Strictly speaking, the only thing
the engine needed was a valve job (guides were fine, just the exhaust
seats had some pitting) and a throttle body cleaning (later versions
got a Teflon coating, mine was an early one that was uncoated aluminum).
I assume a number of things contributed to low wear: the fuel injection,
overdrive, low tension oil rings, etc. but one major contributor has to
be the synthetic oil. When my dad pulled the intake on his 1990 Lincoln's
5.0L, it showed a fair bit of build up that was not present in my engine.
His engine got regular oil changes with conventional oil and certainly
led an easier life than my Mustang. Both my brother and father have
since switched to synthetic oil in their vehcles.
Dad has a Sioux valve grinder so no outside machine work was needed.
I re-used the pistons, rods, block, crank, cam, lifters, pushrods.
Since I wasn't going to need to spend any $$$ on machine work,
balancing or new pistons I had a few dollars left in the budget and
ordered a windage tray and roller rocker arms. I also sprang for
a set of the premium Victor Reinz head gaskets. These came highly
recommended by Alex Denysenko. I replaced the intake mounted sensors
(coolant and intake air temperature) but re-used my Robert Shaw
thermostat as I was not able to find another locally (Autozone used
to carry them). I also reused the oil pressure sender (if it goes
out, it's easy to replace) and all the hoses except for the waterpump
bypass (damaged it). The hoses have a few years on them but are the
Ford Police Mustang extended life blue silicone hoses. They are still
quite pliabe. The parts list looked like:
Bendix coolant temperature sender
Bendix air charge sender
Sealed Power rings (cast iron economy set), standard 4" bore, metric
Sealed Power main bearings (0.002" under)
Clevite 77 rod bearings (0.001" under)
Fel Pro 5.0L HO gasket set
throttle body gasket set
re-used oil temperature sender
Melling M-68 standard volume oil pump (blueprinted)
Victor Rienz 3428SG head gaskets
Edelbrock aluminum water pump
serpentine belt
bypass hose
various vacuum and coolant hoses
Motorcraft ASF 42C spark plugs (copper)
fuel filter
re-used the wires, rotor and cap, all the hoses (all were recently installed)
Permatex Form-a-Gasket 300
Black RTV (use sparingly in corner of pan and intake manifold only)
J.P. Performance double roller timing chain
Comp Cams springs and retainers
Dorman core plug set
dual magnetic drain plugs
block drains (in place plugs)
Ford/Crane "Cobra" bolt-down 1.7:1 ratio roller rockers (with shims)
MPG Head Service windage tray
Paint
Gumout
Paper towels
Pioneer thermactor plugs
Thread sealer
Teflon tape
vacuum hose
fuel hose
vacuum caps
En-valve
Once the engine was out, I started disassembly and cleaning.
For some reason, Ford did not paint the block or heads. With all
the fuel injection, emissions, and accessory stuff on top and around
the engine you don't notice the paint on the heads or block.
I stripped the block and heads clean using rotary wire brushes on
the end of a die grinder. Actually, I used three die grinders with
different types of brushes so I could get into everynook and cranny.
I used a rotary wire brush wheel to remove carbon from the tops of the
pistons, removed the bearings and stuck the pistons and rods in a 5
gallon bucket of carb cleaner overnight. The next day, I rinsed them
off with Gumout spray and wiped them dry with a clean rag. There
wasn't much in the ring grooves, so I didn't use a ring groove cleaner.
I just ran an old ring around the groove to clean out any residue.
The valves cleaned up quickly on the wire brush wheel. Dad did a
standard valve job on the heads and I ground out the bumps in the
exhaust ports with a carbide cutter. This leaves a small hole in
each roof port but with the thermactor holes at the back of the
head plugged, this is of no consequence. BTW, removing the thermactor
stuff makes it much easier to work around the passenger side of the
engine which came in handy when I needed to R&R the starter several
times. The guides and valves (the 5.0L HO OEM valves have chrome
plated stems, BTW) were fine, so I reassembled the heads using the
valve seals from the Fel Pro gasket kit. The intake seals from the
kit were identical to the Ford seals but the exhaust seals were
standard looking umbrella seals with a note indecating they are made
of a superior high temperature type material and don't break down
like old umbrella seals. The OEM Ford exhaust seals were some sort
of hard plastic.
Put it all back together and it runs better than new. Revs great
and still gets 19-20 MPG around town and 24-28 MPG on the highway
(depending upon how fast I drive).
1965 - In July 1965 a running switch was made to a thinner timing chain
and cam sprocket with integral spacer. Pre-1965 (except HiPo)
used a thicker chain with separate spacer. Make sure the stack
height is correct, otherwise the fuel pump eccentric can rub
against the back of the aluminum timing cover.
1965 - 5 bolt bellhousing bolt pattern changed to 6 bolts after November
1965.
1966 - Timing cover change. Pre-1966 timing covers with aluminum water
pumps used a unique timing cover. Most aftermarket aluminum pumps
are for the post-'66 timing covers.
1968 - Timing cover changed to use a bolt on pointer. Earlier timing
covers had integral pointers.
1970 - Water pump inlet (lower radiator hose) changed to from right to
left hand side. This change was coordinated with a change from
3 to 4 bolt crank pulley and harmonic dampers. Many/most
aftermarket dampers are drilled for both types of pulleys.
1975 - Switch for points to electronic ignitions. 1975-1979 Duraspark
module with 3 prongs recommended for swaps to earlier 289/302's.
1977 - Some blocks dropped clutch linkage pilot hole (Mustang II used
cable linkage). Pre-1977 blocks have a holled drilled on the
driver's side rear corner for mechanical clutch release linkage.
1978 - Air injection passage added to cylinder heads. The passage runs
the length of head. The passage can be plugged plugs (available
from Pioneer) which screw into the passage and have threads for
accessory bolts or ground strap. High mileage passages plug up
with carbon. When grinding the humps out of the exhaust ports,
small holes leading to this passage will remain. They are of no
consequence if the end passages have been plugged, otherwise they
will be an exhaust leak.
1978 - EEC-I engine computer introduced on Lincoln Versailles. The crank
is fitted with a pulse ring in place of the oil slinger.
1979 - Changed dipstick to pass through oil pan. Pre-1979 passed through
the timing cover into the front sump pan. 1979 pans have a hole on
the driver's side and pass into a rear sump pan.
1980 - Dipstick location changed again. A hole is drilled into block,
with the dipstick entering the rear pickup oil pan. Note that
Fox-body oil pans have a small forward sump and a large rear sump
with two drain plugs.
1981 Change from 28.2 oz-in to 50 oz-in for 5.0L/302's. All 221, 289,
351W, 351C and earlier 302's were balanced to 28.2 oz-in. Later
5.0L/302 cranks were lightened which required additional mass
added to the harmonic balancer and flywheel/flexplate. It's not
uncommon for late cranks to ...
1985 - Fuel injected engines have the mechanical fuel pump boss blocked
off with a bolt on plate. Later (when?), the boss would be dropped
completely (verify).
1985 - Hydraulic roller cam
5.0L HO Evolution
1982 157 HP @ 4200 RPM
235 ft-lbs @ 1800 RPM
dual snorkel air intake with circular air filter element
2 bbl Motorcraft carb rated at 369 CFM
aluminum intake
8.5 psi mechanical fuel pump
Ford Marine camshaft
1-3-7-2-6-5-4-8 firing order
260/278 degrees duration, 0.416"/0.444" lift
cast aluminum pistons
8.4:1 compression
cylinder block lightened by 15 lbs (relative to 1979 version) to 120 lbs
2-piece rear main bearing seal block and crank
electronic ignition with oil filled coil
D94e-6049-AA cylinder heads (smaller "high velocity" ports and valves)
cast iron manifolds with no exhaust gasket
2" diameter Y-pipe, transverse catalyst, single muffler with dual outlets
SROD 4 speed
7.5" Trac-Lok 3.08:1
Reciprocating assembly changed to utilize 50 oz.-in. balance factor
flywheel and 34 oz.-in. damper Cast
double row roller timing chain
Dual snorkel, high dome cover, low restriction element, air cleaner
1983 175 HP @ 4200 RPM
245 ft-lbs @ 2400 RPM
dual snorkel air intake with circular 17" air filter element
600 CFM Holley 4 barrel carb
8.5 psi mechanical fuel pump
Ford Marine camshaft
1-3-7-2-6-5-4-8 firing order
260/278 degrees duration, 0.416"/0.444" lift
cast aluminum pistons
8.4:1 compression
block and crankshaft revised for one-piece rear main seal
electronic ignition with oil filled coil
D94e-6049-AA cylinder heads
cast iron manifolds with no eexhaust gasket
2" diameter inlet, 2.25" outlet Y-pipe, transverse catalyst, single
muffler with dual outlets
BW T-5 5 speed
7.5" Trac-Lok 3.08:1
1984 175 HP @ 4200 RPM
245 ft-lbs @ 2400 RPM
dual snorkel air intake with circular 17" air filter element
600 CFM Holley 4 barrel carb, redesigned choke, exhaust manifold heat
tubes removed
8.5 psi mechanical fuel pump
Ford Marine camshaft
1-3-7-2-6-5-4-8 firing order
260/278 degrees duration, 0.416"/0.444" lift
cast aluminum pistons
8.4:1 compression
electronic ignition with oil filled coil
D94e-6049-AA cylinder heads
cast iron manifolds with no eexhaust gasket
2" diameter inlet, 2.25" outlet Y-pipe, transverse catalyst, single
muffler with dual outlets
BW T-5 5 speed
7.5" Trac-Lok 3.08:1 (3.27:1 optional)
1985 210 HP @ 4400 RPM
270 ft-lbs @ 3200 RPM
dual snorkel air intake with circular 17" air filter element
600 CFM Holley 4180C 4 barrel carb, diaphragm choke pull down, improved
secondary metering
8.5 psi mechanical fuel pump
hydraulic roller lifters and camshaft
266' duration, .444 valve lift
1-3-7-2-6-5-4-8 firing order
266/266 degrees duration, 0.444"/0.444" lift
steel distributor gear (compatible with roller cam core)
forged aluminum pistons, thinner (metric) low-tension rings, thicker lands
8.4:1 compression
water pump revised with larger 4.4" diameter pump impeller, improved
bank-to-bank distribution
electronic ignition with oil filled coil
E5AE-6049-AA cylinder heads, revised to allow removal of roller tappets
with head in-place
stainless steel tubular exhaust manifolds with no eexhaust gasket
2.5" diameter inlet/outlet Y-pipe, inline catalyst, dual mufflers with
2.25" pipes
BW T-5 5 speed (revised ratios)
7.5" Trac-Lok 2.73:1 (3.08:1 optional)
Revised block (122 lb.) with two retainer bosses for roller tappets.
1986 200 HP @ 4000 RPM
285 ft-lbs @ 3000 RPM
EEC-IV engine control
SEFI (sequential electronic fuel injection)
19 lbs/hr fuel injectors
58mm bore throttle body
long runner EFI manifold
fender mounted flat panel air filter
39 psi in-tank electric fuel pump
hydraulic roller lifters and camshaft
1-3-7-2-6-5-4-8 firing order
266/266 degrees duration, 0.444"/0.444" lift
steel distributor gear (compatible with roller cam core)
revised flat top forged aluminum pistons, metric low-tension rings (lower
tension than 1984)
9.2:1 compression
3.5" diameter water pump impellor with exit scroll
electronic ignition with oil filled coil
E6SE-6049-AA cylinder heads, revised with masked intake valves for
increased swirl and faster combustion
engine block cylinder wall thickness increased (semi-siamesed water
jackets), "squared bores" for better oil control, increased deck thickness
stainless steel tubular exhaust manifolds with no eexhaust gasket
2.25" diameter H-pipe with 4 convertors, and dual 2.25" inlet/outlet
mufflers
BW T-5 5 speed
8.8" Trac-Lok 2.73:1 (3.08:1 optional)
1987 225 HP @ 4400 RPM
300 ft-lbs @ 3000 RPM
EEC-IV engine control
SEFI (sequential electronic fuel injection)
19 lbs/hr fuel injectors
60mm bore throttle body (580 CFM)
long runner EFI manifold
fender mounted flat panel air filter
39 psi in-tank electric fuel pump
hydraulic roller lifters and camshaft
1-3-7-2-6-5-4-8 firing order
266/266 degrees duration, 0.444"/0.444" lift
steel distributor gear (compatible with roller cam core)
revised forged aluminum pistons with 0.03" dish and eyebrows for piston
to valve clearance, metric low-tension rings (lower tension than 1984)
9.0:1 compression
3.5" diameter water pump impellor with exit scroll
electronic ignition with oil filled coil
Truck casting wedge cylinder heads with revised combustion chamber,
casting # E7TE-AA
engine block cylinder wall thickness increased (semi-siamesed water
jackets), increased deck thickness
stainless steel tubular exhaust manifolds with no exhaust gasket
2.25" diameter H-pipe with 4 convertors, and dual 2.25" inlet/outlet
mufflers
8.8" Trac-Lok 2.73:1 (3.08:1 optional)
1988 Basically carryover from 1987
1989-1992 -- 225 HP @ 4000
Same block, heads, intake and exhaust manifolds as 1987
Cast hypereutectic aluminum pistons
Introduction of the 55mm Mass Airflow fuel injection system.
Cams were revised to be quieter, slight power loss over the years.
1993 H.O. -- 215 HP @ 4200
1993 5.0 Cobra
Same cast hypereutectic pistons as 1993 5.0L H.O.
Cast iron GT-40 heads
Shorter duration, higher lift camshaft
1.72:1 ratio rocker arms
Cast aluminum Cobra intake
65 mm throttle body, 24 lbs-hr injectors, 70mm mass air meter
shorty headers
specially programmed EEC-IV for 24 lb/hr injectors
94/95 Mustang GT/Cobra use a shorter distributor (as much as 1/2" shorter
due to moving if the TFI module). To use this you will need the 94/95
Mustang wiring harness, computer, distributor and Ignition box. Also of
worth is the fan control module which will automatically controll cooling
fans
If you go Explorer nose, you HAVE to stay serpentine, the water pump is a
unique item and runs reverse rotation. The PS pump runs up top left side of
motor and I cut that part of the bracket off mine. I then had a guy at work
make a new idler pulley with groves in it to hold the belt and give the water
pump a bit of belt wrap. I was also able to use the stock explorer alt bracket
with tensionser pulley and Alt on the right side, which was very nice!!