Page 1 of 2 12 LastLast
Results 1 to 10 of 13

Thread: Tapping explorer intake for ACT

  1. #1
    Join Date
    Sep 2012
    Location
    N.C.
    Posts
    536
    Feedback Score
    6 (100%)

    Default Tapping explorer intake for ACT

    For those who have done the explorer intake swap, what size drill bit did you use? Also what size tap? I hope to work on my intake this weekend. Thanks for the help...Ray.
    87 Tbird LX w/Factory floor shifter 3G upgrade. Tinted Windows...85 Mustang GT steering wheel(non-cruise) 17'' Saleen SC style wheels,Front/Rear TC sway bars/poly bushings & Mustang GT steering rack...'05 Mustang V6 springs...93 Cobra MC & booster, MM adjustable C/C plates, Work In Progress....... ( On The Shelf---HO computer, 19lb injectors, HO cam, BBK headers, Explorer Intake, Cold Air Intake ,Phantom Gauges, Stinger stainless exhaust pipes )

  2. #2
    Join Date
    May 2005
    Location
    Newmarket, ON, Canada
    Posts
    169
    Feedback Score
    0

    Default

    Act is 3/8 NPT. Drill is 37/64 but may be hard to find. 9/16 will do the trick.

    John

  3. #3
    Join Date
    Feb 2012
    Location
    Grand Rapids, MI
    Posts
    1,824
    Feedback Score
    7 (100%)

    Default

    Centerpunch and pilot hole, for real. Mine's off center a little, and it annoys me whenever I think about it. Hope you're working with a 96 or 97 lower, the later ones don't have a flat boss where the ACT goes. Also, while you're drilling and tapping, you should consider opening the coolant port for the EGR cooler, it's there on the Explorer intake, but like the ACT, it's just a flat boss, so you're left with a return fitting on the coolant manifold, but no coolant feed. I don't recall the drill size, but I'm pretty sure the tap was 1/8 NPT.
    1988 Thunderbird 5.0
    GT40P, TFS-1, KB domes, 30#, MAF conversion, Explorer GT40 Upper/Lower, Smog delete, Wide Ratio AOD Mod, Unlocked Speedo, 3G Charging System Upgrade, Hi-Torque Mini Starter, 3.73 LSD, BBK 1 5/8 unequal headers, H-Pipe.

    88 Thunderbird/Cougar EVTM
    (Thanks to Trinom for hosting)

  4. #4
    Join Date
    Jun 2005
    Location
    Chicago
    Posts
    10,679
    Feedback Score
    17 (100%)

    Default

    +1 on center punching before drilling. Also drill a smaller pilot hole before drilling the 9/16" final hole.
    '88 Thunderbird LX: 306, Edelbrock Performer heads, Comp 266HR cam, Edelbrock Performer RPM intake, Edelbrock 70mm TB, 76mm C&L MAF, 30lb injectors, 2.5" exhaust, AOD with 2800 PI converter, 8.8 with 3.73 gears, 31 spline Traction-Lok, 31 spline Moser axles, 04 Cobra front arms, Maximum Motorsports extreme duty rear arms, subframes.
    '11 Focus, '12 Mustang 3.7, '17 Accord EX-L V6

  5. #5
    Join Date
    Apr 2005
    Location
    NW Ohio
    Posts
    108
    Feedback Score
    0

    Default

    I'm thinking of this swap - what is this "ACT", and is it required with the swap?

  6. #6
    Join Date
    Feb 2012
    Location
    Grand Rapids, MI
    Posts
    1,824
    Feedback Score
    7 (100%)

    Default

    Air Charge Temp, and most definitely yes, you need it.
    1988 Thunderbird 5.0
    GT40P, TFS-1, KB domes, 30#, MAF conversion, Explorer GT40 Upper/Lower, Smog delete, Wide Ratio AOD Mod, Unlocked Speedo, 3G Charging System Upgrade, Hi-Torque Mini Starter, 3.73 LSD, BBK 1 5/8 unequal headers, H-Pipe.

    88 Thunderbird/Cougar EVTM
    (Thanks to Trinom for hosting)

  7. #7
    Join Date
    Apr 2005
    Location
    NW Ohio
    Posts
    108
    Feedback Score
    0

    Default

    Ugg, why can't anything be a bolt-in for our cars?! I'm assuming we can use the stock ACT for our cars, correct?
    Last edited by kewlcoug; 04-28-2018 at 05:33 PM.

  8. #8
    Join Date
    Jan 2005
    Location
    Ardmore,Oklahoma
    Posts
    19,511
    Feedback Score
    135 (100%)

    Default

    Yes. You can use the stock ACT. All you're doing on the Explorer intake is making a place to put that sensor. It's really not hard to do. Don't overthink it. I used about four or five drill bits to make the hole. I started with the pilot hole then gradually moved up with the bits. Made it a smoother operation for me. Easy stuff. Use cutting fluid when you are cutting the threads (tapping) in the intake and make sure all of the metal shavings are cleaned out. It's actually like a 5 minute job.
    '88 Sport--T-5,HURST shifter,Trick Flow R intake,Ed Curtis cam,Trick Flow heads,Scorpion rockers,75mm Accufab t-body,3G,mini starter,Taurus fan,BBK long tube headers,O/R H-Pipe, Flowamaster Super 44's, deep and deeper Cobra R wheels, Mass Air and 24's,8.8 with 3.73's,140 mph speedo,Mach 1 chin spoiler,SN-95 springs,CHE control arms,aluminum drive shaft and a lot more..

  9. #9
    Join Date
    Apr 2005
    Location
    NW Ohio
    Posts
    108
    Feedback Score
    0

    Default

    Thanks for the info - I also found a youtube video that made it seem more manageable. On the youtube video, they also bored out a coolant hose line towards the back of the lower intake manifold, which connects to the throttle body. Did you also bore this hole out, or is it not necessary?

    Also, overall, how would everyone rate the power/torque gain that you get with the explorer intake? I have a mild built motor (bored .040, F303 cam). I've read that with some of the aftermarket intakes you get a loss of low-end torque, and I'd rather not do the swap if that is the same with the explorer intake.

    Thanks!

  10. #10
    Join Date
    Oct 2004
    Location
    Utah.
    Posts
    9,210
    Feedback Score
    2 (100%)

    Default

    You won't lose torque. The intake is the bigfest restriction on these motors once you've done a h.o. swap. More so on the lower.
    Quote Originally Posted by jcassity
    I honestly dont think you could exceed the cost of a new car buy installing new *stock* parts everywhere in your coug our tbird. Its just plain impossible. You could revamp the entire drivetrain/engine/suspenstion and still come out ahead.
    Hooligans!
    1988 Crown Vic wagon. 120K California car. Wifes grocery getter. (junked)
    1987 Ford Thunderbird LX. 5.0. s.o., sn-95 t-5 and an f-150 clutch. Driven daily and going strong.
    1986 cougar.
    lilsammywasapunkrocker@yahoo.com

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •