'97 v8 into '99 XLS with 4406!

[SploderXLT]

Started this project last October, when I started to realize the major things that changed between '98 and '99, I stopped the project and just drove the XLS around with the OHV until the transfer case went out 3 weeks ago. The transmission had some issues as well when i bought it, so I was at a cross road, replace the transmission and transfer case, get a new truck or put the 5.0 in and figure it out. I chose the last path. While I was doing it, I remembered my dislike for the AWD setup in my 97. I found a local junkyard that had a 4406 and both drive shafts I needed for $225.

Bought a new set of v8 engine mounts and threw the motor in. I'd like to take this moment to express how much easier having a body lift makes EVERYTHING!!!

The second thing I didnt like about the v8 setup was those terrible exhaust manifolds. Unfortunately I have another major project going on, so I am not able to put much $$ into this, so rather than buy the headers that are available, I bought a header "kit" and made my own.

I cant find the "finished" picture I took, but they have 3 bolt flanges and are painted black with high temp paint.

The next obstacle was the fuel system, 97 has a return fuel system, the 99 doesnt. Easy to fix, I took the complete fuel sending unit and return fuel line out of the 97 and put it right into the 99, no problem.

the v8 needs a remote solenoid for the starter, the 99 truck had the threaded holes for it, put it on and found the "starter remote" wire that went to the v6 starter, cut it and jumped it to the new solenoid.

There are a few wires in the main harness that arent the same(part of the 98+ update) but it wasnt too bad to figure out when I got the ECU pinouts for both motors. Some of the wires were different colors but went to the same thing. The A/C and ALT harness on the v8 was totally different, but was simple to splice in.

I was concerned about the speedo as the 99 used a sensor on the diff and the 97 used a sensor on the transfercase(which I changed) but the speeo is working fine, the diff sensor must go straight to the dash, not to the ECU.

I'll put up more pics and info later if you guys are interested.

 

[vroomzoomboom]

yup. its so much easier if your swapping from same year, to same year truck. the headers look pretty good to. hope you have no clearance issues. you might have a problem with your tach. you have to swap around two wires in the cluster pin out. did the same swap as you did last year. there is also a few parts that will work from the v6 to the v8's look in my registry, i posted up some of the things i found.

 

[FIND]

What kit did you use? I hate welding header kits, props to you for having the patience for it. Guess lifting the body off helps though, huh? That driver's side looks like it is going to be awful close to the steering shaft though... Passenger looks like it should be good to go though, might want to fab up a heat shield though to run over the top of it so you don't melt all that plastic that goes above it, or is there no AC and whatnot in that truck?

 

[SploderXLT]

It was a summit branded 1 5/8" kit. I would not even attempt making these if I didnt have a body lift! Drivers side is close to the steering shaft, maybe 1/4" there. I do still have a/c, with the body lift, there is plenty of room below the "HVAC" box.

Here is the exhaust I made over the weekend. All 2 1/2", it was a summit branded exhaust kit for a v8 s10 swap.

 

[SploderXLT]

Finally got around to installing the F150 shifter in the truck.

 

[Bruces expo]

Sweet build man ! , I like the DIY headers ! , I'm also a fan of a Body lift for Ease of Repairs and Fixes , It helps me with my current trans problem !

 

[rabbit91]

Beauty! Nice and clean