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Old 05-24-2014, 09:59 PM   #1
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GT40 Heads

Hi Guys,
I'm in the process of doing a 302 / 5.0 Build & I just thought I'd give others a Heads Up on doing this & the problems associated with it. My car is a 94 GT.
The Heads are GT40 (3-Bar) Heads off a 96 Explorer. I'm using a Ford Racing E303 Cam so I have to upgrade my Valve Springs & Push Rods. I'm also using 1.6 Roller Rockers. I'm using Dual Coil Valve Springs with Damper & because of the Cam I also HAVE TO USE VITON SEALS & can not use the stock type as they wont fit the springs or hold the pressure. Doesn't sound like a big deal...But it ads $200 in machine work to the heads to re-size the Valve Guide Bosses & Grind that Step around the bosses down Flat so everything will work.
So you're looking at: $200 = Roller Rockers, $60= Hardened Push Rods, $100 = Valve Springs, $10= Valve Seals, $30 = Rocker Channel Guides, $65 = New Retainers,
$10 = Hardened Valve Stem Locks, +++ $200 in Machine work on top of whatever you pay for the Heads.
Also I think I may have run into another problem with the heads...Not sure yet as this is something I was just told today. I was told the GT40 Heads have no Air Injection Ports for the Smog Pump. I live where I have to pass emissions so ....well...not sure what to do yet. I'd like to delete it but not sure i could get through emissions if I do.
My advice after learning the hard way...DON"T DO IT !!!!!
Buy yourself some aluminum heads as you'll end up paying close to the same price.
The GT40 Intake isn't a Big Deal. On 94-95 Mustangs you have to buy a Throttle Body Elbow & mine I got for $65 New on Ebay.
Hope this helps those decide which way to go who are thinking about doing a build.
Sure wish I'd of Built a 351 instead now.
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Old 05-25-2014, 01:31 PM   #2
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Well, Followed the Smog Pump Lines today & yes...The Stock E7 Heads have Air intake Ports on the backside of them. The 96 Explorer GT40 Heads DO NOT HAVE THESE PORTS.
Another problem. Now to find a Solution.
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Old 05-25-2014, 05:54 PM   #3
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Found someone who's done this swap. He said he bolts the Air Injection lines to the back of the heads to make it look good. Uses the longer Serpentine Belt around the Smog Pump to go through emissions & changes over to a shorter belt eliminating the smog afterwards.
Sooooooooooooo....there you have it. That's how I'm doing it.
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Old 05-27-2014, 02:38 PM   #4
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Just delete that crap and run the smog pump directly to the cats via a heater hose. Keep the stock EGR hooked up since its external. The air injection stuff does absolutely 0 for actually passing the sniffer. Visually I can't imagine someone would notice its gone.

I junked mine right away when I had my 95 and it passed the sniffer with flying colors every time by swapping the stock pipe back in for emissions day.
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Old 05-27-2014, 05:46 PM   #5
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What stock pipe are you talking about ? H-Pipe ? My Exhaust is completely welded in except for at the Headers & Rear Axle. I have all 2.5" Pipe w/ only 2 Hi-Flow Cats, X-Pipe & Cherry Bomb Glass Packs. The Line from the smog pump is welded in near the cats. I did the exact same set up in my 04 3.8 Mustang & it had no problems passing emissions. Hoping this car passes too.
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Old 05-27-2014, 06:26 PM   #6
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As long as you have cats and she passes the sniffer you are good. I did the stock mid-pipe swap every 2 years for emissions day. Only takes 30-45 minutes to swap. But since you can't do the swap just roll with what you have. If it doesn't pass go through with the spout pulled. It'll run like a bag of *** but it should pass.
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Old 05-28-2014, 03:11 PM   #7
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Spout ???
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