Engine swap on 97
Thread Starter
Junior Member
Joined: Sep 2007
Posts: 17
Likes: 0
From: chicago Il
Engine swap on 97
I have a 97 With a 4.6. My grand father bought the truck new and now I have it so it has some sentimantal value and I like power but its just not there. The truck only have 70K on it and it looks damn near new.( its never seen winter). I want to swap a 5.4. Prob from a lighting. Im going to U.T.I. To be mechanic for school so i have a high level of mechanical ability. I was just wondering what do you guys think?
OVERTHINKER
Joined: Mar 2007
Posts: 1,634
Likes: 9
From: Lebanon, TN
The swap is not that hard, you just need to get some other things along with the Lightning motor. First you need to talk to a performance tuner so you can get a tune that will feed the 5.4s air and fuel needs. Remember the 4.6 is running 19lb injectors and the 5.4 Lightning is running 42lb injectors. You will also need to upgrade the fuel pump so it will keep up with the fuel demands.
The other consideration is the tranny, you probably have a 4R70W and the Lightning uses the beefy 4R100. The 4R70W will bolt up and run but a few times of sticking you foot in the Lightning setup because you can't get enough of that blower whine and the 4R70W will be trash.
I say make your Grandfather proud and follow your dreams
The other consideration is the tranny, you probably have a 4R70W and the Lightning uses the beefy 4R100. The 4R70W will bolt up and run but a few times of sticking you foot in the Lightning setup because you can't get enough of that blower whine and the 4R70W will be trash.
I say make your Grandfather proud and follow your dreams
Thread Starter
Junior Member
Joined: Sep 2007
Posts: 17
Likes: 0
From: chicago Il
Can I get the 4R100 to fit in the truck. I know id have to ahve a driveshatft made but thats not a big deal. My best friends dad is a performace trans builder and im ASE certified in the trans department. I just didnt know if that trans will bolt up to my cross member.
OVERTHINKER
Joined: Mar 2007
Posts: 1,634
Likes: 9
From: Lebanon, TN
Notes for 4.6 to 5.4 swap
Exhaust: The collectors on the exhaust manifolds are set at different angles and locations. The 4.6 exhaust will not bolt up to 5.4 manifold. You will need to have a muffler shop modify your 4.6 exhaust to match up.
Ignition: All 5.4 engines use Cop ignition. . 2000 and later 4.6 use COP ignition. 1997-99 4.6 engines use coil packs. It is easier to wire your 5.4 using the harness from the 4.6 and the 4.6 ignition coil packs if applicable. If you use the 4.6 Coil pack ignition you will have to fab a bracket for the driver side coil pack.
Engine harness: The IAC harness must be relocated to the rear of the throttle body elbow. The oil sender wire on the 4.6 may be too short so measure or test fit the harness to see if it must be extended. All 97-00 4.6 engines use some sort of intake manifold runner control valve. Remove it from the 4.6 and plug it into the 4.6 harness and bolt it to the engine some where out of the way. Note you can get a tune to remove its function and eliminate it all together. All 97-98 4.6 engines use an engine coolant temp sensor. Some use 2. None of the 99+ 5.4s use any. You will have to tap the intake manifold crossover pipe to fit the sensor. Some 4.6 engines (97-8) have two sensors.
Transmissions: the 4.6 and 5.4 have the same bellhousing bolt pattern. That means that all the transmissions will bolt up. All the 5.4 engines have 8 bolt crankshafts. Some 4.6 engines (ROMEO ENGINE) have 6 bolt cranks. You will need the flex plate from the 5.4.
Manual transmissions: If you don’t have an 8 bolt flywheel a flywheel from a 1997-8 4.6 Windsor engine will work. As it has 8 bolts it will bolt right up to the 5.4 crank. Remove the flex plate spacer and install a pilot bearing from a 4.6.
Torque Converters.
4R70W
ENGINE Stall Speed Multiplication
4.2 1978-2330 2.3:1
4.6 2105-2505 2.3:1
5.4 1830-2190 1.9:1
4R100
All ?????? 2.2:1
If you swap a 5.4 into a 4.6 engine bay and use the 4.6 converter you will multiply the 5.4's torque at a higher rate and at a higher stall speed which will put the torque at the transmission input shaft close to the limit if not over the limit of the 4R70W. The 99+ 5.4 produces 350 ft/lbs of torque. 90% of that is available at 2000 rpm. The stall speed of the 4.6 is above the 2000 rpm range so more than 90% is available. 350 ft/lbs x 2.3(4.6 multiplier) x 90% is 724.5 ft/lbs.
Tuning: It is best to have a custom tune done to accommodate the extra displacement of the 5.4.
You should be able to use the 4.6 MAF as any competent tuner can adjust for it. It is always best to discuss this with your tuner.
Knock Sensor:
The 97-98 99 4.6 uses a 2 wire knock sensor. The 97-98 5.4 has 3 wires of which one is a ground. Both have a Yellow /red wire to pin 57 on PCM.
1997-98-99-2000-01 Yellow/red to 57 on PCM 4.6 Same for 5.4.
97-98 Pin 91 feeds power for 4.6 and other components. Same for 5.4
1999- 2000-01 Pin 32 for power. Same for 5.4
2002+ Cannot confirm.
Accessories: Some engines have 8 rib serpentine belts and some have 6. Be sure to check so that your accessories have the correct pulley.
Misc: Both engines use the same engine mounts and their location on the block are also the same so your old ones will fit. Unbolt and place aside the AC and PS. You need to remove the intake manifold for the engine to come out. Yes there are 3 bolts on the starter.
Exhaust: The collectors on the exhaust manifolds are set at different angles and locations. The 4.6 exhaust will not bolt up to 5.4 manifold. You will need to have a muffler shop modify your 4.6 exhaust to match up.
Ignition: All 5.4 engines use Cop ignition. . 2000 and later 4.6 use COP ignition. 1997-99 4.6 engines use coil packs. It is easier to wire your 5.4 using the harness from the 4.6 and the 4.6 ignition coil packs if applicable. If you use the 4.6 Coil pack ignition you will have to fab a bracket for the driver side coil pack.
Engine harness: The IAC harness must be relocated to the rear of the throttle body elbow. The oil sender wire on the 4.6 may be too short so measure or test fit the harness to see if it must be extended. All 97-00 4.6 engines use some sort of intake manifold runner control valve. Remove it from the 4.6 and plug it into the 4.6 harness and bolt it to the engine some where out of the way. Note you can get a tune to remove its function and eliminate it all together. All 97-98 4.6 engines use an engine coolant temp sensor. Some use 2. None of the 99+ 5.4s use any. You will have to tap the intake manifold crossover pipe to fit the sensor. Some 4.6 engines (97-8) have two sensors.
Transmissions: the 4.6 and 5.4 have the same bellhousing bolt pattern. That means that all the transmissions will bolt up. All the 5.4 engines have 8 bolt crankshafts. Some 4.6 engines (ROMEO ENGINE) have 6 bolt cranks. You will need the flex plate from the 5.4.
Manual transmissions: If you don’t have an 8 bolt flywheel a flywheel from a 1997-8 4.6 Windsor engine will work. As it has 8 bolts it will bolt right up to the 5.4 crank. Remove the flex plate spacer and install a pilot bearing from a 4.6.
Torque Converters.
4R70W
ENGINE Stall Speed Multiplication
4.2 1978-2330 2.3:1
4.6 2105-2505 2.3:1
5.4 1830-2190 1.9:1
4R100
All ?????? 2.2:1
If you swap a 5.4 into a 4.6 engine bay and use the 4.6 converter you will multiply the 5.4's torque at a higher rate and at a higher stall speed which will put the torque at the transmission input shaft close to the limit if not over the limit of the 4R70W. The 99+ 5.4 produces 350 ft/lbs of torque. 90% of that is available at 2000 rpm. The stall speed of the 4.6 is above the 2000 rpm range so more than 90% is available. 350 ft/lbs x 2.3(4.6 multiplier) x 90% is 724.5 ft/lbs.
Tuning: It is best to have a custom tune done to accommodate the extra displacement of the 5.4.
You should be able to use the 4.6 MAF as any competent tuner can adjust for it. It is always best to discuss this with your tuner.
Knock Sensor:
The 97-98 99 4.6 uses a 2 wire knock sensor. The 97-98 5.4 has 3 wires of which one is a ground. Both have a Yellow /red wire to pin 57 on PCM.
1997-98-99-2000-01 Yellow/red to 57 on PCM 4.6 Same for 5.4.
97-98 Pin 91 feeds power for 4.6 and other components. Same for 5.4
1999- 2000-01 Pin 32 for power. Same for 5.4
2002+ Cannot confirm.
Accessories: Some engines have 8 rib serpentine belts and some have 6. Be sure to check so that your accessories have the correct pulley.
Misc: Both engines use the same engine mounts and their location on the block are also the same so your old ones will fit. Unbolt and place aside the AC and PS. You need to remove the intake manifold for the engine to come out. Yes there are 3 bolts on the starter.
