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