Fuel Stock 1994 5.0 throttle body size

[GOvert]

I have a 5.0 project going that includes a stock 1994 5.0 intake assembly. It is NOT the GT40 style intake. It is the style first used on the 1991 Thunderbirds.
What is the stock bore off the throttle body? 58mm, 60mm? I have a 65mm '98 Explorer throttle body that I was hoping would fit however, it has more of a square pattern whereas the 94 Mustang pattern is a bit more rectangular. Someone somewhere said that a 1996 Mustang 4.6 TB or a 1999 Crown Vic TB might bolt on, but I don't want to start buying parts that won't fit or purchase unnecessary performance parts for this engine which is primarily for Interstate travel or as local as going up to Sonic to get a half price after 8 shake. Thunderbird underhood file photo below.

My recent purchase below of parts for 5.0 #2.

I purchased these parts and the PO said that they didn't perform as expected. I see the restriction. I know that this isn't by far the best flowing 5.0 intake that is available however, I think the throttle body could be bumped up to 65-70mm. My coil-near-plug "proof of concept" 5.0 in my 1997 Mercury has a 65mm throttle body. The Explorer/Mountaineer engines have the 36-1 sensor ring on the HB that makes coil-near-plug fired 5.0s even possible. I'm using Ford sedan PCMs from c-o-p powertrains.
Picture below of the 97MM 5.0 in progress. Rain delay...

This picture is of the first fit of the coil-near-plug brackets that I designed. Now that the 2020 7.3 "Godzilla" engine exists, Ford coils are available to do coil-near-plug instead of a "cross company" coil swap. You have to use a PCM designed with 8 coil drivers. In the 5.0 Explorer/Mountaineer wasted spark PCMs there are only 4 coil drivers. The harness is near complete, and the intake is almost ready for the 19# 1999 Crown Vic fuel injectors to go in.
More later on the first engine and I'm still working on the throttle body part of 5.0 #2.

 

[General karthief]

First it appears that you have a explorer/gt40 lower so I believe that upper intake will not work, second the throttle body will be a net gain of zero, you need an explorer throttle body.

 

[GOvert]

@General karthief Re-read. You are looking at two different engines.

 

[General karthief]

Yes, the first pick, as I read it, is a random pic of the T bird engine compartment, the second is his engine fitted with COP brackets. Unless my dyslexia is kicking in

 

[GOvert]

The first pic is of a 1991 Thunderbird that first used the intake assembly that some 1994 Mustangs came with if the didn't have the GT40 style.
The 2nd pick is of (my) the 1997 Mercury Mountaineer engine that has the GT40 style intake assembly. My first c-n-p project.
The 3rd pick is the intake assembly for my 1994 Mustang GT that did not have the GT40 style. It is getting converted to OBDII to coil-near-plug too.

 

[GOvert]

I thought that I had found a solution. I removed a 1999 Crown Vic throttle body. It fit on the 1994 intake with room to spare. Then I realized that it doesn't have an IAC on it. Bore was good though. 65mm. Oh well.

 

[Mustang5L5]

The stock TB size for the 94-95 Mustang was 58mm.

A popular mod for the 94-95 crowd was to do a Foxbody throttle body conversion. Much better selection of aftermarket throttle bodies available. The Explorer 65mm can also be made to work, although you'll want to pay attention to the TPS sensor mount. The earlier ones used fox mustang style sensors while later ones used unique explorer TPS sensors.

Also, bellcrank may not be compatible with what you want to do, but since I dont know what you are doing i'll leave it there. There are conversion articles to further convert the explorer throttle body to work on a Fox mustang. I run such a converted 65mm TB.

However given that the 94-95 HO intake (the 91-93 t-bird style intake) was rather anemic, not going to be a huge gain upping your TB beyond 60/65mm.

 

[GOvert]

@Mustang5L5 Thanks for replying. Friday, I mulled over several ideas and have determined that I need to make a 1" thick adapter out of aluminum to be able to use the Explorer throttle body. The engine is for a truck project and it will be using an Explorer 5.0 throttle cable. 58mm to 65mm is 12% larger.
As it may sound like I would be tuning an engine to fit a tune, bin file, I'm wanting to use the same parts as my first 5.0. 19lb injectors (it's not a race engine) 65mm Ex throttle body and "Godzilla" coil set. Later I will up the injector size a bit when I move up to a 2003 Marauder pcm and Explorer intake assy.
The pic on post #6, shows the flange of the 1994 plain 5.0 intake. After the sun comes up, I will get a better picture. Of the flange. I won't be able to get a pic of the throttle body until Monday.
I had kind of a drastic idea to have the bolt holes of the '94 intake flange filled in by welding then drill a new hole set to match the Explorer throttle body.
There is not enough surface area on the 94 Mustang flange to do such and I didn't really want to modify a near antique part. I need to find a good young Machinist that it a Ford fan to help me out on the machine work for the adapter.
Pic below of the first bit of design scratch.

 

[GOvert]

Face of 1994 intake flange. Rectangular and not as large as the explorer throttle body face.

1998 Ford Explorer throttle body gasket larger than 1994 intake flange.

1"x5"x5" piece of T6061 for flange.

Are there any good and quick machinist here that I can ship "if it ships, it fits"?
I need an ~ 65 to 70 mm hole machined through the plate in a specific place and trim two edges. Soon!
Notes to self: '94 flange bolts need to be 1/4-20 Allen head bolts to go through the 94 flange an no deeper than 7/16" into spacer.
Front bolt holes for the Explorer throttle body 7/16" deep for 5/16-18" studs with nuts.

 

[GOvert]

I have the aluminum in hand and a machinist lined up to make a 65mm hole. That is the 98 Explorer tb bore size, and the limitation of the
T-bird style intake.

Both throttle body gaskets stacked to plot out where the 65mm hole will go.

('94 Mustang gasket is sitting a tad crooked)