02 XLT 4x4 4 Dr 'E' Code 'K' Code Question ...

[Stangly]

Hey all, I searched for hours looking for an answer to this question without any luck. Hence this thread. I have a 2002 XLT 4x4 4dr 4.0 v6 'K' Code flex fuel with a bad bottom end (blown rod) literal hole in block. Replacing motor. Question: can I use a block from a 'E' Code motor and transfer all my 'K' Code (top end, exh man, etc) stuff over to it and be ok? Only reason I ask is cause 'K' Codes here are few and far between and are also almost twice as much $$, and that's if you can find one. The 'E' Codes are a dime a dozen. I know I can use an 'E' Code block, as long as it came from a 4x4 (balance shaft). But are the 'E' Code heads ok, or would I have to use the 'K' Code heads? I dont mind doing the extra work to save a few bucks, but would hate to be spinnin my wheels for not. Any help would be greatly appreciated ... Thx -Dave-

 

[Stangly]

Luckily I found a used 'K' code motor out of a 4x4. They're pulling it now and I'm picking it up Friday. Now just gotta hope the engine swap goes smooth. I've r&r'd 4.0L's in the Rangers before so the Explorers should be quite similar. Any tips or 411 would be greatly appreciated. This is going to be a 'weekend warrior' job outa my own garage on my back, lol. Cherry picker and stand red to go. Getting ready to make a big ole mess!

 

[Stangly]

Is there a hidden bolt on these? Everything set to pull motor, all 6 bellhousing bolts are out (4 top, 2 bottom), starters out, 4 tc nuts are off, I cant get this motor to seperate from the tranny. Tried prying, no luck. Any tips?

 

[Joscibo]

Is there a hidden bolt on these? Everything set to pull motor, all 6 bellhousing bolts are out (4 top, 2 bottom), starters out, 4 tc nuts are off, I cant get this motor to seperate from the tranny. Tried prying, no luck. Any tips?

If I remember correctly there are 8 in the bell. 2 below 1 on each ear and 4 up top. I did a 4.0 swap out of an 08 Mustang swapped my components. Worked amazingly well.

 

[EXPLORER04]

The manual is showing 8 bellhousing bolts

 

[Stangly]

I found the two bolts. One I cant believe I missed and the other one was recessed on top right near one that was out. Motor is free, I thought I'd have enough room without removing the radiator, nope, has to come out. Almost there ...

 

[Stangly]

Update, radiator did not have to come out. Not only did the radiator stay put, so did all the AC and PS components, didn't have to break a line, all intact. Removed main bracket and kept everything connected, strung off to side, and all was good. Bonus, the TC stayed put also, no seals to deal with. Pics are coming, I' know, it was a tight squeeze, but has been done, YAY!

 

[Stangly]

Here's pic of HOLE in old block ...

 

[Stangly]

TC intact ...

 

[Stangly]

AC & PS intact ...

 

[Stangly]

Both motors out ... swappin exterior stuff ... havin fun!

 

[Stangly]

Update: New(er) motor is in, went in np with the radiator, ps, & ac intact. Will update again soon. Still have a bunch of minor stuff to get done. Again, this job was done solo out of a one & 1/2 car attached home garage. Hopefully she'll fire up when the time comes ...

 

[Dave8338]

Nice work. Done that a few times but never on an Explorer. Keep us posted.