Engine swap
98 F150 5.4L E40D/4R100
Joined: Nov 2006
Posts: 28,519
Likes: 7,630
From: MI
Thanks for the reply.
I just ran all the numbers down and the short block will interchange, so that makes it a fairly easy swap out. The 04 has the 8-9 thread spark plug holes, so that is a big bonus.
Doing a bit more research on the 04 2v, it has the bigger crank and heavier rods, which is an upgraded design. They also list both cast and aluminum blocks in that year. This one is cast.
Since 97-98 don't have a PATs system, I don't see any kind of electrical problem, just using the original harness. I may have to switch injectors from the 98 to fit connectors, but that isn't a big thing. You have to use the 98 intake anyways, so the whole top is off the engine, why not do everything while its open. I'll be using factory intake gaskets to rule out the leaking problem with the newer heads, so that is one thing that is remembered.
Any other thoughts of possible problems?
What I'm not comprehending, is why the Expedition motor only shows fitting Expy's and Navigators. I'm wondering if there is an oil pan change or hopefully not a front cover. I'm reading where in 03 they redid the cover fitment on one of the lower left bolts. Not something you think about being a problem. I don't see a difference, but there has to be something that is definitely different between and Expy and F150 in 03-04(H). Anyone know what that difference might be. I hate surprises. I get enough of them on my own, without an engine being another one to add to my list. lol
I just ran all the numbers down and the short block will interchange, so that makes it a fairly easy swap out. The 04 has the 8-9 thread spark plug holes, so that is a big bonus.
Doing a bit more research on the 04 2v, it has the bigger crank and heavier rods, which is an upgraded design. They also list both cast and aluminum blocks in that year. This one is cast.
Since 97-98 don't have a PATs system, I don't see any kind of electrical problem, just using the original harness. I may have to switch injectors from the 98 to fit connectors, but that isn't a big thing. You have to use the 98 intake anyways, so the whole top is off the engine, why not do everything while its open. I'll be using factory intake gaskets to rule out the leaking problem with the newer heads, so that is one thing that is remembered.
Any other thoughts of possible problems?
What I'm not comprehending, is why the Expedition motor only shows fitting Expy's and Navigators. I'm wondering if there is an oil pan change or hopefully not a front cover. I'm reading where in 03 they redid the cover fitment on one of the lower left bolts. Not something you think about being a problem. I don't see a difference, but there has to be something that is definitely different between and Expy and F150 in 03-04(H). Anyone know what that difference might be. I hate surprises. I get enough of them on my own, without an engine being another one to add to my list. lol
Last edited by Jbrew; Nov 11, 2016 at 01:39 AM.
98 F150 5.4L E40D/4R100
Joined: Nov 2006
Posts: 28,519
Likes: 7,630
From: MI
Thanks for the reply.
I just ran all the numbers down and the short block will interchange, so that makes it a fairly easy swap out. The 04 has the 8-9 thread spark plug holes, so that is a big bonus.
Doing a bit more research on the 04 2v, it has the bigger crank and heavier rods, which is an upgraded design. They also list both cast and aluminum blocks in that year. This one is cast.
Since 97-98 don't have a PATs system, I don't see any kind of electrical problem, just using the original harness. I may have to switch injectors from the 98 to fit connectors, but that isn't a big thing. You have to use the 98 intake anyways, so the whole top is off the engine, why not do everything while its open. I'll be using factory intake gaskets to rule out the leaking problem with the newer heads, so that is one thing that is remembered.
Any other thoughts of possible problems?
What I'm not comprehending, is why the Expedition motor only shows fitting Expy's and Navigators. I'm wondering if there is an oil pan change or hopefully not a front cover. I'm reading where in 03 they redid the cover fitment on one of the lower left bolts. Not something you think about being a problem. I don't see a difference, but there has to be something that is definitely different between and Expy and F150 in 03-04(H). Anyone know what that difference might be. I hate surprises. I get enough of them on my own, without an engine being another one to add to my list. lol
I just ran all the numbers down and the short block will interchange, so that makes it a fairly easy swap out. The 04 has the 8-9 thread spark plug holes, so that is a big bonus.
Doing a bit more research on the 04 2v, it has the bigger crank and heavier rods, which is an upgraded design. They also list both cast and aluminum blocks in that year. This one is cast.
Since 97-98 don't have a PATs system, I don't see any kind of electrical problem, just using the original harness. I may have to switch injectors from the 98 to fit connectors, but that isn't a big thing. You have to use the 98 intake anyways, so the whole top is off the engine, why not do everything while its open. I'll be using factory intake gaskets to rule out the leaking problem with the newer heads, so that is one thing that is remembered.
Any other thoughts of possible problems?
What I'm not comprehending, is why the Expedition motor only shows fitting Expy's and Navigators. I'm wondering if there is an oil pan change or hopefully not a front cover. I'm reading where in 03 they redid the cover fitment on one of the lower left bolts. Not something you think about being a problem. I don't see a difference, but there has to be something that is definitely different between and Expy and F150 in 03-04(H). Anyone know what that difference might be. I hate surprises. I get enough of them on my own, without an engine being another one to add to my list. lol
Crap, I don't know what I did, but I lost half my post here.
This sucks. - I'll cut to the end, as far back as I can recall lol. Folks are still using the 04+ 4.6L blocks for gen 10 swaps. Seems to me, any 2V 5four should be the same on the exterior. The Expy's have EVO steering, the 150's did not AFAIK. IMO that shouldn't effect the swap, but it's a difference that they may of considered without knowing for sure. But again, I think it's just 3V vs 2V thing with most 5fours going 3V that very same year. I'm betting the 04 Expy 2V is fully compatible w/the 98. I would get the PCM flashed for the AF's to be in tune/sync with PI intake and heads, after your done. Just Flash for PI, nothing else. That Flash or upload should be quick. I would be supervised if they charge more than .5 labor.
Well now my post appeared above this one...jeezz, this site must have went on the fritz momentarily because it disappeared for awhile. Well now you have two posts from me a little different from one another lol. Hope it helps lol.
Last edited by Jbrew; Nov 11, 2016 at 02:20 AM.
Senior Member
Joined: Jul 2010
Posts: 8,544
Likes: 2,552
From: Alaska
Where I am, and getting things shipped up here, I'll have to pass. The freight on an engine palletized from just Seattle to Anchorage is up to 5-600, so that makes that a tough pill to swallow. This is why, when I found this Expy and it had the newer designed engine parts, for $350, why not? 103k miles. I think that it might be a decent enough endeavor. I appreciate the thought though.
If it wasn't for Amazon and their free shipping on certain items, I would of never have gotten my rear window louvers. They were the only place that would ship to Alaska, and I got the discounted price, and they paid the freight.
I also wanted a Cervani hood for my Mustang but it would of been 650 to ship that sucker from CA to AK. All that cost for shipping a $599 hood. It just doesn't compute in my head spending that kind of money for shipping. I finally found one here in AK, and got it for 300. It is in the shop right now being painted and will make it's first appearance on Sonya in the spring. I'll post pictures then, with the new grabber blue stripes.
If it wasn't for Amazon and their free shipping on certain items, I would of never have gotten my rear window louvers. They were the only place that would ship to Alaska, and I got the discounted price, and they paid the freight.
I also wanted a Cervani hood for my Mustang but it would of been 650 to ship that sucker from CA to AK. All that cost for shipping a $599 hood. It just doesn't compute in my head spending that kind of money for shipping. I finally found one here in AK, and got it for 300. It is in the shop right now being painted and will make it's first appearance on Sonya in the spring. I'll post pictures then, with the new grabber blue stripes.
98 F150 5.4L E40D/4R100
Joined: Nov 2006
Posts: 28,519
Likes: 7,630
From: MI
What mods, it's a straight up swap with your intake ? I believe some Expy's ran an extra idler, top left. Are you getting just the engine or can you pillage from the doner if need be ?
Last edited by Jbrew; Nov 11, 2016 at 11:01 PM.
Senior Member
Joined: Jul 2010
Posts: 8,544
Likes: 2,552
From: Alaska
By mods, I was talking about the 03 and 04 having a larger rotating assembly, over the 99-02, and 97-98, and the newer, upgraded heads with the 8-9 threads.
As far as to what I got, I took everything with the exception of the starter and the alternator. I took the wiring harness, the exhaust, etc. I didn't leave much in the hole where it came from. I even took the AC compressor. I didn't waste my 350. I took full advantage of what he gave me. I read over 3 hours of stuff on this swap, and didn't want to have any kind of oops down the road.
Thanks for the assistance.
As far as to what I got, I took everything with the exception of the starter and the alternator. I took the wiring harness, the exhaust, etc. I didn't leave much in the hole where it came from. I even took the AC compressor. I didn't waste my 350. I took full advantage of what he gave me. I read over 3 hours of stuff on this swap, and didn't want to have any kind of oops down the road.
Thanks for the assistance.
98 F150 5.4L E40D/4R100
Joined: Nov 2006
Posts: 28,519
Likes: 7,630
From: MI
By mods, I was talking about the 03 and 04 having a larger rotating assembly, over the 99-02, and 97-98, and the newer, upgraded heads with the 8-9 threads.
As far as to what I got, I took everything with the exception of the starter and the alternator. I took the wiring harness, the exhaust, etc. I didn't leave much in the hole where it came from. I even took the AC compressor. I didn't waste my 350. I took full advantage of what he gave me. I read over 3 hours of stuff on this swap, and didn't want to have any kind of oops down the road.
Thanks for the assistance.
As far as to what I got, I took everything with the exception of the starter and the alternator. I took the wiring harness, the exhaust, etc. I didn't leave much in the hole where it came from. I even took the AC compressor. I didn't waste my 350. I took full advantage of what he gave me. I read over 3 hours of stuff on this swap, and didn't want to have any kind of oops down the road.
Thanks for the assistance.
So in those 300 pages, did it say anything about using a second Idler? Or did you notice.
Senior Member
Joined: Jul 2010
Posts: 8,544
Likes: 2,552
From: Alaska
There was one spot in the other forum that told about the idler problem and such. Thanks to that, I went ahead and took everything there was. Why have to go looking later? I believe in being thorough when it comes to a swap that I've not had to do before.
You mentioned also, that there was an under intake valley possible problem with the newer blocks. When I ran this block number, it came up 02 and later. That is what I based my research on after that. I also picked up on having to use my E40D flex plate, since the Expy has the 4R70w.
There was a lot of information provided. It was one of the ones where you have to almost read all of the posts, due to all the possible problems. I think that I have more than enough parts to make me happy. I will find out when it gets installed. I appreciate all the info you provided here, and in the other forum.
the dog.
You mentioned also, that there was an under intake valley possible problem with the newer blocks. When I ran this block number, it came up 02 and later. That is what I based my research on after that. I also picked up on having to use my E40D flex plate, since the Expy has the 4R70w.
There was a lot of information provided. It was one of the ones where you have to almost read all of the posts, due to all the possible problems. I think that I have more than enough parts to make me happy. I will find out when it gets installed. I appreciate all the info you provided here, and in the other forum.
the dog.
98 F150 5.4L E40D/4R100
Joined: Nov 2006
Posts: 28,519
Likes: 7,630
From: MI
There was one spot in the other forum that told about the idler problem and such. Thanks to that, I went ahead and took everything there was. Why have to go looking later? I believe in being thorough when it comes to a swap that I've not had to do before.
You mentioned also, that there was an under intake valley possible problem with the newer blocks. When I ran this block number, it came up 02 and later. That is what I based my research on after that. I also picked up on having to use my E40D flex plate, since the Expy has the 4R70w.
There was a lot of information provided. It was one of the ones where you have to almost read all of the posts, due to all the possible problems. I think that I have more than enough parts to make me happy. I will find out when it gets installed. I appreciate all the info you provided here, and in the other forum.
the dog.
You mentioned also, that there was an under intake valley possible problem with the newer blocks. When I ran this block number, it came up 02 and later. That is what I based my research on after that. I also picked up on having to use my E40D flex plate, since the Expy has the 4R70w.
There was a lot of information provided. It was one of the ones where you have to almost read all of the posts, due to all the possible problems. I think that I have more than enough parts to make me happy. I will find out when it gets installed. I appreciate all the info you provided here, and in the other forum.
the dog.