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Chris - sorry to reply late to your email (and via the BB for mass consumption) but took a few days off last week and my 'net access is better at work.
Take the following advice with the grain of salt that I didn't build my car (PO did) but only have experience trying to rework some of its shortcomings.
The 5.0/AOD into 700 can be a tight fit mostly b/c of the AOD having either a bigger bellhousing or greater length than a T5 (or both). As such, it cannot be mounted as far back and pushes the motor closer to the rad. I suppose if your rebuild plans allow, you could try to move the eng/trans pkg. closer to the firewall with some choice hammering to it and/or shortening the driveshaft a bit.
My setup sounds similar to yours: 93 5.0/AOD in a 1988 760 wagon, with GM 16" fan mounted on studs off-center from the engine. Waterpump pulley is less that 2" from my radiator, so a shroud is near impossible too. My original diesel rad was having trouble cooling my car, so I had a 6-cyl 760 rad re-cored with a copper-brass three row core. My rad guy recommended maximum 14 fins/inch whereas Yount's guy said more like 16-18, but both suggested 3 half-inch tubes which yields a core thickness of about 2". As Michael said below, he had the core offset in the tanks towards the front for still more clearance. Sorry I don't have a decent digital camera or I'd try posting a pic or two.
My rad has had no trouble cooling my mostly stock 5.0 and I my only cooling ambitions involve a DCController and center-mounting the fan in a 760 shroud after gaining more front clearance by moving the rad forward so it sits underneath the plastic rad cross-piece. I have already helped things by adding a huge Power Stroke trans cooler under the front bumper and plumbed the trans cooling without using either the built-in log cooler in the rad or the auxilary Volvo cooler in between the rad and the AC condenser. I may also use a smaller Cobra high flow water pump pulley (with corresponding crank underdrive pulley and alt pulley) to ease the crowding of my fan setup (can't get the belt off without moving the fan on its studs!). Not looking to speed up coolant flow but just better clearance between rad and engine.
Fans I have considered are the Taurus (can't get enough clearance), the Ram Chargers dual fan setup (ditto) and the IST fan (see http://www.mustangmonthly.com/howto/11879/). Also check out this corral thread:
http://www.corral.net/forums/showthread.php?t=546249
From what I can tell, the IST fan may well be the same GM 16"-er I currently have, so I plan to first try mounting it in the 760 shroud like IST does.
Another option I have considered is fitting the entire complement of SN95 accessories on the engine since the lower hoodline of 94-95 Mustangs required Ford to redesign all the brackets to be make the engine package about 1.5" shorter. This would be pretty pricey unless you could get a deal at the JY.
Hope my reply was worth the wait and that conversely (sorry for the pun) I didn't ramble beyond your patience... -Boozer
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88 760 wagon 5.0 & AOD
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