5.0 swap mish mash

[blueka]

I've got a 97 UK spec sohc and it's got bad rod knock and timing chains.

I've also got a 98 5.0 2wd with a bad trans.

I've also possibly got the chance to grab a 2001 5.0 4r70w and tcase.

My 97 doesn't have pats. The 98 does.

What all would I need to do/ parts to get to make this shmozzle work?

Si

 

[CDW6212R]

Those are good donor parts, and great given how they are becoming more scarce.

If the 98 is the whole truck, that's the best parts you need to swap to the V8. You can use most of that, including the 98 engine harness, and ideally you'd like a late 1997 5.0 PCM. That's the best swap computer, it has no PATS, it uses the same EGR system and heads etc, as the 98-01 V8's, though it does need an analog trans range sensor(DTRS on the side of the trans, at the shift linkage).

The 98+ 4R70W has the better guts and wiring, so use that with the pre-98 range sensor(DTRS(that has to match the PCM model(the 1997 PCM has to have the 1997 DTRS))).

What condition is the engine? The age and care some have gotten over high mileage often creates oil consumption, and most of that is at the heads(valve guides). So if you can, have the heads reconditioned with new guides etc, valve job, and replacement level springs. I have three 98 302's, my first never used oil(well taken care of), but the last two eat it fast(a quart a week). They all have the same mileage, but the last two obviously didn't have the oil changed properly.

 

[blueka]

The engine has 250k on it. Needs new manifolds and a couple of seals.

Remember I'm in the UK. 5.0 was never sold here and my 97 is RHD

Si

 

[Turdle]

Is the 98 2wd V8 right hand drive?

 

[CDW6212R]

The engine has 250k on it. Needs new manifolds and a couple of seals.

Remember I'm in the UK. 5.0 was never sold here and my 97 is RHD

Si

That will be interesting, the RHD I have imagined trying to fit a 302 into a USPS Explorer based mail truck. They made one called an FFV which has a 1999 2nd gen Explorer SOHC chassis, 2WD or A4WD. The right hand exhaust manifold could be a major issue to fit the 302 into that RHD model. The steering shaft is very close to the engine and the 5.0 explorer has a unique OEM manifold made to work with the shaft on the left side. You might be able to take some measurements of your RHD truck around the steering shaft, to try to figure out if it will clear using the 5.0 manifold in your truck.

I'm sure you can find an engine machine shop there who can work on the V8 heads, they are very easy to work with. The engine might be fine to use as is with that mileage, depending on the prior care as I said. The heads are fairly easy to R&R to have refurbished like I suggested, when the engine is out. The cost should be about $75 for the head gaskets, $150 or so for a quality valve spring kit, plus the labor to install new valve guides and the rest. Replace the injectors also if they are an unknown age.

You can probably also use the old cat pipes if they haven't been hurt by anything chemically. I don't know your emissions laws, but there are decent universal cats which can work for under $100 each(only two are needed, strict emissions laws like CA require four high dollar units).
All three of my 302 Explorers have about 225k miles on them, and one will be a project truck that I will refresh the engine for a short term reuse(new engine much later). I'll rebuild the heads and install new front and rear main seals, water pump etc. If the core engine is okay(the cylinder walls not worn badly), the engine can last a bunch of years to come. But the valve springs and guides get worn out by this age, they need help if it's possible to do it.

For the engine wiring, with that 98 harness, Jamie can help with the minor changes to make to it. The 1996/97 system used slightly different wiring in that engine harness, just a few wires, versus the 1998 and 99-01 systems. Don't let that worry you, but be concerned about the handling of the wiring a lot, both removing the engine and the wiring while doing the swap. That wiring is very fragile at this age, you don't want to create any breaks inside the wiring looms, which can be trouble later. The injector connectors will likely break, but those can be replaced easily.

 

[blueka]

Hi Jon!

No, the 98 EB is LHD...

Si

 

[boominXplorer]

All good points here. To sum it up your major hurdles will be wiring and the steering shaft clearance.

I'd get a 97 v8 engine bay harness and 97 v8 engine / trans harness to make the swap happen without pats. Should make the whole ordeal nearly plug n play unless they changed fuse box sides on the RHD model. A 97 model us spec v8 harness would be the closest start and easiest to obtain. If you get a late 97 harness it will have the later 98 yr range sensor on the transmission and match everything on the 98 plug for plug except the valve body plug but that's an easy one.

Can you take some under the hood firewall pics of the 97 RHD?

 

[blueka]

I will have a go this afternoon

Si

 

[CDW6212R]

I should have pictures myself of the RHD models, the SOHC mail truck version. But I have never made time at work to take a few. It is much tighter under the hood of the mail truck, because they shortened the front end as much as possible. But the space inside the bay is the same as all of the 2nd gen SOHC models, same radiator, engine etc. The changes are along the firewall, the brakes and steering are all on the right side.

 

[blueka]

I couldn't get into it. Battery is flat and the door locks have seized. Interestingly the 98 5.0 is working again

Si

 

[CDW6212R]

The 302 is very hard to kill, other than neglect and old age corrosion of the timing cover/bolts, they can last a long long time. That sounds like a fun project, if the steering shaft will clear the right manifold.