Will the Tork Tech kit fit the '96-98 Mustang?
Yes, but let's discuss the issues you need to know.
The TTI kit is designed for the '99-04 Mustang GT engines (plus other 2V applications) that have the "PI" or "Product Improved" cylinder heads but it is not absolutely necessary to swap to the later heads. Just as many non-PI owners over the years have installed the PI intake on to their engine to bump up power the same idea can be done if you wish to install a Tork Tech kit on to your non-PI engine. The Tork Tech lower intake is sort of a PI intake but it is of course designed for a supercharger so this intake can be retrofitted to a non-PI engine as well. Just Google "Installing a PI Intake on a Non-PI engine" and I'm sure you will find numerous posts and how-to instructions on the Internet that show proper gasket techniques for this task.
The TTI kit utilizes a separate supercharger drive which is a very important design feature. The Cross Brace which locates all the supercharger belt tensioners and idlers is designed to fit the PI engines. There is a interference issue with the belt tensioner if the old front timing chain cover is utilized, so the older cars will need to switch to the newer design. These are easy to find in salvage yards or on auction sites for around $50-75. In addition to the front cover note that the idler arms and idler pulleys will be different also so get all these also from a donor car. For instance, one of the idler pulleys on the older cars is flat while the new style uses a grooved pulley. Overall, you need to make the belt drive system exactly like the '99+ cars.
Another minor issue that the older GTs will need to deal with is that they have the dual coil pack type ignition while the newer cars have the individual coil on plug (COP) type. There are actually two ways to solve this issue. You can simply relocate both coil packs and purchase a generic set of plug wires that you cut to length to fit the new coil pack locations, or you can switch the car over to the COP ignition. Switching to the COP is actually alot easier than you would guess as there is a simple wiring modification that is shown numerous places around the Internet that allows you to run the individual coils. We suggest you go this route as it will clean up your engine bay compared to having ignition wires running all over the place. It may be a bit more expensive but if low mileage used coils are located the cost can be minimal.
The PI cylinder head change (or properly gasketed non-PI heads) and the front timing chain cover assembly are really the only physical changes that are needed to allow the kit to bolt in place but there are a couple other differences between the '96-98 models and the '99-04 models that affect the TTI supercharger kit. The first is the difference in fuel pumps. The older models us a "Return" type system, while the newer models use the "Non-Return" type. I have been also told that the return type fuel rail interferes with the supercharger on the older cars. You can reuse this rail but you will likely have to rework the cross tubes from one side of the rail to the other. Also, the computers and therefore the computer tunes will be different. If using non-PI heads then be aware engine compression is raised slightly so be sure to tell your tuner about this and he may elect to decrease timing at high engine RPM to negate the chance of knocking/pinging.
One last thought is that it is VERY easy to simply swap in place a complete "PI" engine in place of your "NPI" engine. With this swap your car will immediately fit the TTI kit and perfect fitment is guaranteed. Excellent low mileage examples of PI engines are available in salvage yards everywhere and if you can choose we recommend the '02-04 models as minor enhancements make these the best engines out there. Typical costs range from $500-1500 for a nice engine. Don't forget your donor engine can come from any application where the 4.6L 2V engines were used, not just from a Mustang. Overall, this really is the easiest way to go to achieve a reliable power plant that allows for easy fitment with the Tork Tech supercharger setup.
The TTI kit is designed for the '99-04 Mustang GT engines (plus other 2V applications) that have the "PI" or "Product Improved" cylinder heads but it is not absolutely necessary to swap to the later heads. Just as many non-PI owners over the years have installed the PI intake on to their engine to bump up power the same idea can be done if you wish to install a Tork Tech kit on to your non-PI engine. The Tork Tech lower intake is sort of a PI intake but it is of course designed for a supercharger so this intake can be retrofitted to a non-PI engine as well. Just Google "Installing a PI Intake on a Non-PI engine" and I'm sure you will find numerous posts and how-to instructions on the Internet that show proper gasket techniques for this task.
The TTI kit utilizes a separate supercharger drive which is a very important design feature. The Cross Brace which locates all the supercharger belt tensioners and idlers is designed to fit the PI engines. There is a interference issue with the belt tensioner if the old front timing chain cover is utilized, so the older cars will need to switch to the newer design. These are easy to find in salvage yards or on auction sites for around $50-75. In addition to the front cover note that the idler arms and idler pulleys will be different also so get all these also from a donor car. For instance, one of the idler pulleys on the older cars is flat while the new style uses a grooved pulley. Overall, you need to make the belt drive system exactly like the '99+ cars.
Another minor issue that the older GTs will need to deal with is that they have the dual coil pack type ignition while the newer cars have the individual coil on plug (COP) type. There are actually two ways to solve this issue. You can simply relocate both coil packs and purchase a generic set of plug wires that you cut to length to fit the new coil pack locations, or you can switch the car over to the COP ignition. Switching to the COP is actually alot easier than you would guess as there is a simple wiring modification that is shown numerous places around the Internet that allows you to run the individual coils. We suggest you go this route as it will clean up your engine bay compared to having ignition wires running all over the place. It may be a bit more expensive but if low mileage used coils are located the cost can be minimal.
The PI cylinder head change (or properly gasketed non-PI heads) and the front timing chain cover assembly are really the only physical changes that are needed to allow the kit to bolt in place but there are a couple other differences between the '96-98 models and the '99-04 models that affect the TTI supercharger kit. The first is the difference in fuel pumps. The older models us a "Return" type system, while the newer models use the "Non-Return" type. I have been also told that the return type fuel rail interferes with the supercharger on the older cars. You can reuse this rail but you will likely have to rework the cross tubes from one side of the rail to the other. Also, the computers and therefore the computer tunes will be different. If using non-PI heads then be aware engine compression is raised slightly so be sure to tell your tuner about this and he may elect to decrease timing at high engine RPM to negate the chance of knocking/pinging.
One last thought is that it is VERY easy to simply swap in place a complete "PI" engine in place of your "NPI" engine. With this swap your car will immediately fit the TTI kit and perfect fitment is guaranteed. Excellent low mileage examples of PI engines are available in salvage yards everywhere and if you can choose we recommend the '02-04 models as minor enhancements make these the best engines out there. Typical costs range from $500-1500 for a nice engine. Don't forget your donor engine can come from any application where the 4.6L 2V engines were used, not just from a Mustang. Overall, this really is the easiest way to go to achieve a reliable power plant that allows for easy fitment with the Tork Tech supercharger setup.
