Engine Early Explorer Lower EGR Coolant Fitting

sav22rem22 · Feb 10, 2021

So I recently bought an early explorer upper and lower with the act already drilled and tapped however the egr coolant fitting hasn't been drilled and tapped. Does anyone know what thread I would need to tap it to? And would I be able to swap the fitting from my stock lower over? Sorry for making another explorer intake thread I just couldn't really find this specific bit of info.

Deleted member 215073 · Feb 10, 2021

I believe it's 3/8 NPT.

Mustang5L5 · Feb 11, 2021

Yes, 3/8NPT. Stock intake fitting will swap over

sav22rem22 · Feb 11, 2021

Mustang5L5 said:
Yes, 3/8NPT. Stock intake fitting will swap over

Thanks so much. You guys are life savers

sav22rem22 · Feb 12, 2021

Mustang5L5 said:
Yes, 3/8NPT. Stock intake fitting will swap over

So I also see on your picture of the explorer upper, it has the stock 5.0 HO vacuum tube on it. I'll show some pictures of mine for comparison but I'm assuming they have to be drilled and tapped to look like that one?

Mustang5L5 · Feb 12, 2021

Correct, also 3/8 npt.

see this thread

Engine - Explorer intake vacuum line diagram

Have seen this question asked a million times. So here's a diagram. This is an EARLY Explorer intake with the EGR port. There were two lower manifolds. The RF-F87E-9K461-BA lower was early and had the bosses present for the ACT. The RF-F87E-9K461-BB lower was later (non-EGR) and lacks the...

www.stangnet.com

sav22rem22 · Feb 12, 2021

Mustang5L5 said:
Correct, also 3/8 npt.

see this thread

Engine - Explorer intake vacuum line diagram

Have seen this question asked a million times. So here's a diagram. This is an EARLY Explorer intake with the EGR port. There were two lower manifolds. The RF-F87E-9K461-BA lower was early and had the bosses present for the ACT. The RF-F87E-9K461-BB lower was later (non-EGR) and lacks the...

www.stangnet.com

Okay thanks. When tapping for 3/8 npt on the lower for the egr coolant port do you recommend using a 9/16 bit? I know the correct is 37/64ths but i know thats going to be a real pain to find. Also when drilling it out should i start with a smaller bit first and work my way up?

Mustang5L5 · Feb 12, 2021

Yes, but it will be tight. You’ll want a sharp tap and use plenty of cutting fluid and clear the tap often.

the 37/64 tap would be more ideal, and you can get those at Amazon or Home Depot if you order online and ship to store.

if you have any concern with cracking the intake, go with 37/64

sav22rem22 · Feb 18, 2021

Mustang5L5 said:
Yes, but it will be tight. You’ll want a sharp tap and use plenty of cutting fluid and clear the tap often.

the 37/64 tap would be more ideal, and you can get those at Amazon or Home Depot if you order online and ship to store.

if you have any concern with cracking the intake, go with 37/64

Alright I’ll go with a 37/64. I’ve watched a video on the fitting and it seems much much thinner than I originally thought so it shouldn’t be bad if I take my time and do it right. Thanks for the help

Mustang5L5 · Feb 18, 2021

Just pay close attention to the photos in the link I provided earlier. You can see that the pipe fitting fits rather close to the intake plenum. As such I would recommend favoring a slight angle away from the plenum to allow the fitting to thread in nicely. Not much, maybe 1-2 degrees away. You can see by the pics what I mean

Engine Early Explorer Lower EGR Coolant Fitting

sav22rem22

Deleted member 215073

Mustang5L5

That is…until I whipped out my Bissell

sav22rem22

sav22rem22

Mustang5L5

That is…until I whipped out my Bissell

Engine - Explorer intake vacuum line diagram

sav22rem22

Engine - Explorer intake vacuum line diagram

Mustang5L5

That is…until I whipped out my Bissell

sav22rem22

Mustang5L5

That is…until I whipped out my Bissell

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Engine Early Explorer Lower EGR Coolant Fitting

Deleted member 215073

That is…until I whipped out my Bissell

That is…until I whipped out my Bissell

That is…until I whipped out my Bissell

That is…until I whipped out my Bissell

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