4.0 SOHC died, so going 302 swap. Need your help. Letter to Mods at opening.

[Blacksheep Josh]

Moderators, I am putting this into the modified Second Generation Forum because I feel I will get the most benefit from this area. This is the generation the engine is coming from and as it being an engine upgrade it most definitely qualifies as a Modification. I just don't feel that this being in the Ranger section will help that great. (I am posting on Ranger websites as well to gather as much information from as many sources as possible). If I am mistaken please move it to it's proper location, I will not object. I just wanted to clarify my actions. (If this is okay can you make note and remove this opening as not to clutter the thread).

As the title says my 01 Ford Ranger Edge isn't doing too well. Chains have been replaced all ready and less then 60k later it's started again. I'm not gonna sink the time nor money into fixing it again when I can find GOOD, used parts and upgrade to a V8 302.

Goal of this thread: Currently the goal of this thread is to collect a parts list of items and services that will be needed to complete the swap in a timely manner. I have seen a few threads where this has been done in a few days, I'm giving myself 3 months. That puts the date on March 3rd to be back up and running. I want to beat this date by as many days as possible.

I'm calling upon those that have done this swap. Give me any problems and solutions and fixes I probably don't realize yet.

Here is what I know I will need this far:
-Engine
-Transmission
-Custom Driveshaft
-Will have to drill new holes for transmission crossmember
-Will have to create/combine battery harness from Ranger/Explorer
-Will have to get Ford to mate the Explorer engine to the PATS system in Ranger.
-Will have to figure out speedometer/speed sensor issue

I believe the harness/computer will plug into the current locations, I just need to get the computer/harness for the 302 motor.

Here are my main questions
-What year Explorer 5.0L had PATS?
-What year Explorer 5.0L motors were better? Wasn't there a change in head design?
-Will any year Second Generation Explorer 4r70w work? (are the plugs the same for the computer?)

Help me! This first post will be edited to include a parts list as I do it for future reference for anyone else.

Godspeed.

 

[Dono]

A few guys have done the swap.
You have some reading to do.
Here's one:
http://www.explorerforum.com/forums/showthread.php?t=234672&page=8

As you learn and start having real questions, your going to get better responses from people.
You will notice Tim used a donor truck. This looks like it saved a ton of pain.

 

[vroomzoomboom]

here are some things you will need.


rad/condenser ***update, 4L SOHC rad/condenser will work***
a/c lines
power steering lines, and cooler
motor harness, and wiring from alt to battery ***update, 4L underhood body harness will mate to 5L motor harness, however, oil gauge wire, and a/c wires need to be modified to work***
throttle cable
trans shifter cable (not sure if i will need it, but hey) ***update, 5r55e cable will work***
air filter box ***update 4L SOHC box, and sensor will work***
exhaust from manifolds to muffler
fuel pump (not sure if needed but.....) ***update, 4L SOHC pump will work***
g.e.m.
p.a.t.s.
key ring around ignition cylinder, and ignition cylinder
locks including hatch lock
radio bezel
computer
cruise motor with cable

98 is when the explorers started with pats
i cant say for sure, but i think the more desired motor was the mid 97 and up. they had the "P" headed gt40 casting.
the trans i am not sure about.
i am also sure you know to try and stay with the same year donor, as your truck to avoid any wire issues that my slow you down.
when you have everything running, you may also notice that your tack is fast. you will need to move two wires in your cluster harness, but you can still use your cluster.

also, i had found this after i did my swap. it pretty much says the same things that i did

http://www.therangerstation.com/tech_library/5_0_swap_in_newer_ranger.html

if you havent already, you can look into my registry. i tried to document as much as i could. if i missed something, bluka should also have it in his thread "pickle" (the link to his build is on my first page).

all in all, this swap i think scares a lot of people with the info that is provided, but once you dig into it, it is just like swapping any motor out, and can go fast if you do your reading. if you read up on it, and start into this project, everything will fall into place.
happy hotroding!

 

[Blacksheep Josh]

New question to get answered: Fuel system, do i have return line or returnless. Will look at truck when daylight happens and will post edit to first post when figured out.

 

[vroomzoomboom]

98 and down ex's have return fuel systems. 99 is when they changed. i THINK rangers fallowed that as well.....i think. that also will come into play. you will, or should for ease of swap try and find a donor with the same fuel system.

 

[shadowless127]

try and find a totalled 99up Ford 5L that way you can just do a complete swap job.

Not sure if you're 2WD, but remember that the only t-case from the factory that will be a plug and play swap is the BW4404 AWD case, unless you want to do a 4406 swap.

Also, when dealing with PATS it's best to try and get the ignition cylinder/mechanism, PATS module and keys from the same exact truck. Will probably make life a lot easier.