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Got the 5.4 dropped in and working through a few wiring harness changes. I'm having to put a street 45° to clear the 5.4 block for the oil sending unit. I had to change the oil filter assembly because the donor motor was out of a 2 wheel drive and the sending unit was sticking out the bottom and almost on top of the front differential. Minor change. I've still got to extend the wiring harness for the IAC because it is located on the back side of the throttle body housing not like the 4.6.
Next is to get the crank position sensor hooked up. I think the harness is long enough to make the connection and to the AC.
So far this has been a easy swap. The manifold Y pipe is going to be another story! I can't find a muffler shop around here that will bend the 4.6 pipe to fit the 5.4 manifolds! This has surprised me!! So rather than spending $600-700 on a new pipe I'm just going to cut and weld the pipes and fit them myself! The O2 sensors need turned 90° towards the Trans on both sides! They are hitting the floor boards and obviously the wrong angle to connect to the flanges on the 5.4 manifolds.
Does anyone know a cheap way around having to chop up my original Y pipe to make this work? The cheapest pipe I can fine out of a junk yard is $300 and new they are over $700.
I'm building this on a budget and the program for the computer has already put me over budget on this project.
The only real difference on the 2002 trucks is the air pressure valve in the bottom of the intake Plenum. So far that's been the only difference in the harness and sensors between the 4.6 and the 5.4. If i want to spend another $300 for the spacers i could use the 4.6 intake and not have to take the pressure sensor out of the system.
Does anyone know of any other problems I might run into on the final stage of this project?
Any heads up will be grateful.