GT40 Explorer Intake Prep – What do I need?

[kas_lar]

Hi all,
I drive a 1995 Mustang GT 5.0 (SN95) and I’m preparing to install an Early Explorer GT40 upper/lower intake. I’d really appreciate a checklist or advice from anyone who's done this before — I plan to keep EGR unless it becomes overly complicated.


Current mods:

• BBK 75mm throttle body (runs great, smooth idle)
• Cold air intake (stock MAF & housing)
• Pypes Bomb catback – already installed and sounds great!
• Aftermarket high-flow midpipe (upgraded catalytic converter pipe)
• Everything else engine-related is stock, and I don’t plan further engine-upgrades
• The car is only used as a summer cruiser and for occasional spirited fun

Intake details (from seller):

• Early Explorer style (link: https://www.therangerstation.com/tech_library/1996-2001_ford_explorer_v8.shtml)
• Assembled upper/lower
• Gaskets to heads are cheap via RockAuto - send links if you've got them.
• Porting not needed – should already outflow the stock HO intake

What I’m unsure about:

• Do I need a 75mm EGR spacer to match the TB and mount throttle cable?
• IAT sensor – tap the lower intake or relocate to intake pipe?
• Coolant line for EGR – tap the rear boss?
• Vacuum routing – what lines do I need to cap off, and how exactly should I do that? Do they need to be welded shut or is a cap enough?
• Any surprises or small parts I should prep for?

Would love any guides, links, videos or build threads where people document the process — that would really help!


Thanks!
– Kasper

 

[Terrorist 5.0]

Hi all,
I drive a 1995 Mustang GT 5.0 (SN95) and I’m preparing to install an Early Explorer GT40 upper/lower intake. I’d really appreciate a checklist or advice from anyone who's done this before — I plan to keep EGR unless it becomes overly complicated.


Current mods:

• BBK 75mm throttle body (runs great, smooth idle)
• Cold air intake (stock MAF & housing)
• Pypes Bomb catback – already installed and sounds great!
• Aftermarket high-flow midpipe (upgraded catalytic converter pipe)
• Everything else engine-related is stock, and I don’t plan further engine-upgrades
• The car is only used as a summer cruiser and for occasional spirited fun

Intake details (from seller):

• Early Explorer style (link: https://www.therangerstation.com/tech_library/1996-2001_ford_explorer_v8.shtml)
• Assembled upper/lower
• Gaskets to heads are cheap via RockAuto - send links if you've got them.
• Porting not needed – should already outflow the stock HO intake

What I’m unsure about:

• Do I need a 75mm EGR spacer to match the TB and mount throttle cable?
• IAT sensor – tap the lower intake or relocate to intake pipe?
• Coolant line for EGR – tap the rear boss?
• Vacuum routing – what lines do I need to cap off, and how exactly should I do that? Do they need to be welded shut or is a cap enough?
• Any surprises or small parts I should prep for?

Would love any guides, links, videos or build threads where people document the process — that would really help!


Thanks!
– Kasper

(Channel name: “mustang 4life” video name: “Gt40 intake manifold 94&95 mustangs looks&info”)

There is a video on YouTube video specifically for SN95 5.0’s, should be no issue finding it, couple tips I can give you from what I’ve heard:

1. When going to attach the upper to the lower, have it all assembled. The fit and finish isn’t too great with the adapter.

2. Use RTV for the lower intake when sealing it to the “China Wall” as it is commonly called. The cork gaskets are allegedly hard to position properly and are quite sensitive (personally cork gaskets work fine for me)

3. You may have to remove the upper and re-torque everything after a couple heat cycles if you start having unexplained vacuum leak symptoms. It has happened to a couple people.

4. Do an oil change after. That way any dirt or debris that may have fallen in the motor gets drained out of the motor.

You will need the adapter, most of them are 75MM so you will be ok.

You shouldn’t need a coolant line for your EGR. This is a Foxbody thing.

You also shouldn’t need to drill and tap anything in your lower intake. The IAT sensor for SN95 cars is in the intake plumbing.

Only surprise I can think of is breaking a bolt or two when removing the lower intake. The bolts pass through coolant passages if I’m not mistaken and can get pretty stuck. If you do break a bolt, be careful removing it, because if you can’t, the heads have to come off.

The GT40 intake will really wake the car up past 3500 RPM, but you will lose a little below that. You don’t lose enough to notice it though. A stock ported HO intake is ideal for a stock headed stock cammed 5.0.

I like where you are going with your project, and will keep following along

 

[ttocs]

if you go with a non-sn95 cobra intake you will also need the fox body throttle cable IIRC.

 

[Terrorist 5.0]

if you go with a non-sn95 cobra intake you will also need the fox body throttle cable IIRC.

And TPS too if I’m not mistaken, but he is trying to use an adapter

 

[96blak54]

A big thick line of black rtv sealant on the china walls!

 

[RAU03MACH]

did they put a mark up on that RTV from china

 

[ttocs]

not after the judges ruling last night.
taco

 

[kas_lar]

Thanks everyone!
I’ll stock up on RVT sealant

I’m a bit confused about the adaptor between the GT40 explorer manifold and the 75mm BBK TB
Would this adaptor work:

Edelbrock EFI Throttle Body Adaptor (Elbow) Ford Mustang 94-95 w/ Blac

The Edelbrock 38353 adapter kit is required to install our Performer 5.0 PN 3821 or Performer RPM PN 7126 in 1994 and 1995 Mustangs. The 1994-1995 throttle body has a different bolt flange and idle air motor than 1987-1993 models. It is also swung out 50 Deg and dropped 1 degree from its...

drifthq.com

A thread on the adaptor:

https://stangnet.com/mustang-forums/threads/gt40-intake-on-94-95-5-ol.903538/

 

[Terrorist 5.0]

That adapter should work yes. Comes with all the hardware, gaskets for adapter to intake and adapter to throttle body, and even includes an EGR valve gasket. I believe that is 75MM inner diameter as well.

All you do is bolt the adapter to the intake, and bolt whatever you had on the stock intake onto the adapter. I don’t recall exactly what, but stuff like the TPS, IAC, and for sure the EGR.

 

[ttocs]

Just an FYI, if you have not already got the 75mm tb the throat on the GT40 intake is only 70mm. You can port it to 75 and if you have the time/tools go for it but if not you might be able to save a few bucks with a 70mm and not lose any performance.

 

[Wmac]

You don't need a fox body egr agapter, what you will need is an sn95 throttle body adapter. It is a 45 degree elbow. sn95 egr valve bolts to this adapter.
IIRC, fms sold a 65mm piece, pp/mac was 70mm, tf is 75 mm. (eddy was either 65 or 70mm).

You will also need to modify and plug some of the vacuum outlets.

This may give you some ideas.

 

[kas_lar]

Quick (kind of) urgent question: I have the option to buy a used Trick Flow adapter: 5150SN95-00.
Can anyone confirm whether this part fits the early GT40 intake and my 75mm BBK throttle body?
The seller has sent me the screenshot.
Thanks!

 

[Terrorist 5.0]

Quick (kind of) urgent question: I have the option to buy a used Trick Flow adapter: 5150SN95-00.
Can anyone confirm whether this part fits the early GT40 intake and my 75mm BBK throttle body?
The seller has sent me the screenshot.
Thanks!

It should fit

 

[kas_lar]

Small update.
I bought the Trick Flow elbow used from a neighboring country – Sweden. The gasket is broken and old, but I’ll need to get this gasket set: TFS-515GSN95.


The GT40 upper and lower intake should be shipping this week or next week, and I can take pictures of it soon.

 

[Terrorist 5.0]

Small update.
I bought the Trick Flow elbow used from a neighboring country – Sweden. The gasket is broken and old, but I’ll need to get this gasket set: TFS-515GSN95.


The GT40 upper and lower intake should be shipping this week or next week, and I can take pictures of it soon.

If finding the proper gasket proves difficult, you could always make your own. People have used crazy stuff as gaskets and had a successful seal.

By the looks of it, Mustang parts are not easy for you to come by at all due to where you live. Unfortunate.

 

[joemomma]

Local parts stores sell "gasket maker" kits. Basically sheets that you trace/cut out new from your existing bad/damaged gasket.

 

[kas_lar]

Thanks again for all the tips so far — super helpful. I've recieved the GT40 intake and cleaned it up. I have more questions and I hope for some help here


Vacuum ports — what should I cap/remove vs. keep?
On my GT40 (early Explorer) upper/lower intake I count around 3 on each side

For a ’95 GT with stock EEC-IV and EGR retained, which of these should go directly to a device, which should feed a vacuum tree/distribution, and which should be capped?


Sensors (just to confirm):

• IAT/ACT: On SN95 the IAT sits in the intake tube, so I don’t need to drill/tap the lower — correct?
• EGR coolant: SN95 does not need the Fox-style coolant line to the EGR — correct?

---

Gasket plan (please confirm part numbers):

• I’ll buy a DIY gasket sheet and cut my own elbow ↔ throttle body gasket.
• I want new gaskets for:
  • Lower ↔ cylinder heads
  • Upper ↔ lower plenum
• I’m looking at Fel-Pro MS95952 for the intake set — can someone confirm if MS95952 is the right set for a GT40 (Explorer) on a ’94-’95, or should I be using MS93334 (or something else)?
  • If there’s a better one-stop set that covers upper↔lower + lower↔heads, please link it.

• I’ll run a thick bead of black RTV on the china walls (no cork), and dab RTV at the 4 corner joints.
• Re-torque after a couple of heat cycles if needed.
  
  
  
  Small parts — am I missing anything?
  • Pipe plugs for unused ports (likely 1/8" NPT brass) — sizes to confirm?
  • New upper & lower intake bolts/washers (if recommended) and anti-seize.
  • EGR gasket (for the trick flow elbow).
  • TB ↔ elbow studs/bolts if my used Trick Flow elbow is missing hardware.
  • Coolant elbows/O-rings if any are disturbed during the lower swap.
  • PCV valve + grommet + screen refresh while I’m in there.
  • If anyone has a definitive vacuum routing diagram for a ’94-’95 GT with GT40 Explorer upper/lower and EGR kept, that would be gold. Links/part numbers very welcome. Thanks!
  
  
  — Kasper
  ’95 GT Convertible, BBK 75mm TB + SN95 elbow, CAI, stock MAF, high-flow midpipe, EGR retained

 

[96blak54]

Are you planning to clean up the manifold, maybe paint it?
Grab some rotary brushes for a hand drill to clean up the lower manifold oxidation. Looks like the upper plenum coating is still good.

 

[Wmac]

See my pics from post #11 above. (Explorer vs cobra upper) The 3 front ports are n/r, cap or plug them. The tubes are a press fit, vice grips and heat with propane torch to remove. Easy to tap with either 1/8 or 1/4 pipe tap.

 

[shovel]

If it's within budget I'd get that vapor blasted & then paint it.