A completely insane/stupid 4.9l swap. Yes, I'm serious.

[natd001]

Hey guys, I'm new around these parts, and being that I didn't see a section specifically for motor swaps, I figured I'd post here, and a mod can move me if I happen to be in the wrong place (stoopid newbs, amirite? ) So this is a engine-swap thread, I'll try not to keep you guys in too much suspense. Anyways, I happened to come across a steal of a deal on a 2nd vehicle for myself... A 2000 Exploder 4-door, 4wd auto with 117k mi on the clock. The price? A righteous $200. How so? One of my ex's t-chains let loose in the ol SOHC, and they wanted $3900 to fix it, but with the repairs and diagnostics the shop needed $200 to cover the bill for repairs they had made. I told her, "I'll give ya $200 for it, if you don't keep it or junk it." They wanted it off their property, and a text and $200 later, voila, 10yo truck that doesn't look half bad.

Here's where the swapping comes in. I was going to rebuild the engine, I was looking through the parts list and the parts weren't too bad... That is until I got to the timing chains and tensioners. O'Reilly's wanted like, $640 for the entire set. I looked at the cost of rebuilding or the cost of another SOHC (around $800, by my estimates), plus putting in a new t-chain/tensioner set, and either way, it was in the $1400 range, minimum. *WELL* I happen to have an '89 F-150, 4.9l (with 145k, it sat for 9 mos without me touching it, and it turned over on the 2nd crank, and it didn't even knock!!! ) 4wd, with the ZF-5, in storage that I was going to swap a Cummins into, but as it would turn out, this dumb-arse kid didn't do his research, and a ZF-5 behind anything other than a 460 or a diesel WON'T work due to the bolt-pattern difference. Go me. Wouldn't be the first time...

So, as my '89 is just rotting away (a good amount of body cancer, I would assume a fair deal of it being done while in the possession of the previous owners: landscaping company), and I'm nowhere near having the Cummins in running condition (not to mention, I'd need another ZF-5 and around $1200 in conversion equipment) I figured, "Hey, why not swap into the Exploder?"

Heartbreak soon ensued as I discovered that the I6 is a whopping 33.5" in length, from rear of engine to water pump pulley OH NOES!!! Wait... You've got a knack for ridiculous ingenuity, insane ideas (like my '93 yamaha with an 07 GSXR engine and Kawi suspension), and being cheap. If you own it, why not play with it? So, the way I'm figuring it, I'm going to have to fab a 4" (minimum) drop-back fire-wall housing for the engine, lift it with a PA 883 BL to help clear the beast, and move the motor mounts around. Also on the to-do list is getting the driveshafts length-corrected and the correct U-joints for the T-case. I may have to clock the t-case, I'm not for sure yet. I haven't gotten the motor pulled yet (gotta get the garage cleaned out, I'm sure the apt mgmt would LOVE to see me pull an engine swap in their parking lot ) and then after that, I'll be able to see what I'm working with.

I know there's still a bunch of stuff I have to do. Right now, it's getting late, I've had a few beers, and it's been a long week. It's cold here, and it's dark by 5:30, and I get home around 4, so progress will be a bit slow until I get it into the garage (also, working 2 jobs doesn't help me any...). I have however, in the last 2 days that I've started working on it, come very close to getting the dash removed.

This was day one, I didn't get much done to it today, a few more bolts removed and connectors disconnected, but nothing special. The plan is to retain the Exp's computer, and wire as little as possible into the dash gauges. I'm going to disconnect the MIL lamp, and I think the tach, but I assume the rest of the controls will work. What I could really use from you guys is a diagram of the Exp instrument panel wiring, or point me in the direction or book of one, as well as a wiring diagram for the IP of an '89 f-150 with a 4.9l. Also, it would be of great help if somebody could help me out with advice on how to get the black defroster piece pulled up from the dash. I can't see how it's connected exactly, and I've put some serious effort into trying to pull it up, but I'm worried about getting overzealous and shattering it.

Any direction, help, advice, etc is welcome. No, I'm not going to put a 5.0l pig in it. Trying to do this on the cheap. Plus, what's the good in a 5.0l Exploder, if it's already been done?

I'll update as this goes along. Sorry for the long-winded intro, it's the way I am.

 

[wood1]

sounds interesting, good luck and welcome to the site.

 

[Joe Dirt]

Sounds fun!

CLICK ME

 

[natd001]

Thank you for the link! This truck is gonna be a sort of "test bed" being as it's the second vehicle (although it may become primary, as I'm not exactly fond of my Blazer...), and it'll be interesting to mod the ol 300 (only one of the most reliable Ford engines, IMO)...

 

[Joe Dirt]

Those inline 6's are workhorse engines. I love 'em...

 

[natd001]

The last one I owned had 185k on it, and it still ran like a top! The auto tranny went on it and if the E40D wasn't $900 for a rebuild (WITH the core, no less), I would've kept that truck. They're not known for power, but it's as close as I can get to a 4BT's torque for next to nothin'

 

[RangerX]

This is gonna be good. I love the 4.9! I was under the impression though, that it came with the ZF in some models, in some years?

 

[natd001]

There are ZF-5's in the older F-series, as I have one behind the 4.9 that's going in the Exp, but unfortunately, there's 2 different bolt patterns. A SB pattern behind the 300, 302, and 351, and the BB behind the 460 and 7.3, and from what I've read, you can't use one from a SB in a Cummins conversion, I would assume due to clutch/flywheel size limitations. But that ZF in the X is gonna be neat!

 

[kert0307]

Sounds like a fun swap. I'm in the middle of putting a 300 into a B2. Unfortunatly I've gotten a little sidetracked from it because I started a boat project halfway through it. The b2's and explorers are pretty similar. There might be some helpful pictures for you in my B2 project threads. I am going to run an NP435 and a D20 though.

Edit: Watch that oil pan, it's pretty deep!

 

[Glen4X4]

Nice, can't wait to see this build.

 

[Carguy3J]

Ummmm. I'm afraid I've got to throw a "pointless, expensive, illogical" motor swap flag on this play.
First, your $$ for just fixing it as it was built (ie, another SOHC) are off. Yeah, if you went for a full rebuild on your motor, it's gonna cost you. However, you can get a salvage complete, relatively low mileage SOHC motor from a late model Mustang ('03-'10). Let's say you pick one up for $800-$1000, somewhere between 40-70k on it, with a warranty. Now, all you have to do is swap your top-end stuff (intake,injectors,etc..) and the front dress from your current motor, and stick it in the hole. Now you've got a running/driving usable vehicle, which still has some resale value. You could have this done in a weekend. You have a vehicle, and will have not pissed off the apt. manager (as much). If you really want to play w/ that 4.9L,etc..., you could now sell your intact Explorer, for a very nice profit, and go buy a nice F150 to "play" with.

As for this "swap", it's just a bad idea. You gain nothing, as the 4.9L is a bigger, heavier, lower power hunk of iron.

Oh yeah, then there is another BIG issue. Inspection/emissions: You'll NEVER pass with a 4.9L in a 2000 Explorer, because they didn't come that way from the factory. Also, you're '00 Explorer is an OBDII vehicle, whereas the 4.9L and ecm you have are OBDI. Instant fail. What's that you say? No inspection in your state/county? Maybe not yet, but it's coming. The greenies have/will made/make sure of that. Even if you don't have to worry about it for a while, where you are, that means you've built something that can't be sold/registered into somewhere that does have inspection. What if you have to move? You will have spent all that time and money for something you may not be able to take with you, and would have minimal value to someone else.

I like the idea of motor swaps in general, when they accomplish something worth the time,effort, and money involved. This is not one of those. You will spending ALOT of time, MONEY, and effort to do something that, in the end, really wasn't all that great. That's assuming you even complete it. I suspect that you will end up destroying an otherwise serviceable vehicle, and end up w/ an unfinished project that gets hauled off to the scrapyard when your apt. manager threatens eviction.

Like I said, stick a later SOHC long block in it, and move on. The '03 up have improved timing components, and you should have no trouble from a low-mileage salvage motor.

 

[1AJeremyD]

A big ol tower of power in an explorer? This one is going to be good!

 

[kert0307]

Ummmm. I'm afraid I've got to throw a "pointless, expensive, illogical" motor swap flag on this play.

What's that you say? No inspection in your state/county? Maybe not yet, but it's coming. The greenies have/will made/make sure of that. Even if you don't have to worry about it for a while, where you are, that means you've built something that can't be sold/registered into somewhere that does have inspection. What if you have to move? You will have spent all that time and money for something you may not be able to take with you, and would have minimal value to someone else.

Says the guy who has in his signature that he's going to remove his CATs...

(stirs pot )

 

[Joe Dirt]

Zing!

 

[natd001]

Kert- thanks! I haven't taken a full look at your thread, but it looks like you may have a bit more room in your engine bay. If so, you're a lucky dude! From firewall to rad support, I think the X had like, 31.5-32 inches. Haven't pulled the engine yet, there may be a tad more room once I get the engine out and the BL installed. Btw, how much is lpg where you're at? I was looking at possibly making this a bi-fuel at some point down the road...

To everyone with encouragement- also thanks! Glad to see I'm not the only one who's excited to see something like this

Oh carguy, how you've exposed my youthful folly. Such a fool I was to ever consider such an endeavor. All the issues you just covered, I figured need not be said in my first post (it was already long-winded), but I'm well aware of the issues involved. I had thought about swapping in another engine and selling it to some unsuspecting pawn like you said, but where's the fun in that? Also, who said I wanted to get rid of it? The greenies can take it when they pry it out of my cold, dead hands. Same with my weaponry. Its a possible candidate for a cng/bi-fuel somewhere down the road, so it would possibly qualify as a LEV/ULEV with the conversion. I live in NE, which is generally miles behind the curve as far as regulating vehicles and such, so I aint too worried. Worst case scenario, I sell it to some kid on a farm if/when it happens. Also, I'm certified as a D215 welder at my job. Torches, BIG welders, and even an awesome plasma cutter to help me fab stuff. And who wants to do a swap that's "logical"? I never thought I'd see a merlin engine in a 55 or 57 Chevy, COMPLETELY illogical, but by far one of the coolest things I've ever seen in my life. Ditto the Mustang with the Sherman tank engine. Plus, I've got most of the parts I need, its just a matter of elbow grease to make it all work.

 

[Joe Dirt]

That's a 4 Chocodile reply!

 

[Carguy3J]

Says the guy who has in his signature that he's going to remove his CATs...

(stirs pot )

I can hide that. I saved the heat shields, and welded them over the straight pipe, carefully covering the holes in the shields. When they stick the mirror under the truck, it looks like it has cats. The computer tune takes care of the rear O2's

You can't hide a 4.9L in an Explorer, nor can simulate the OBDII computer that won't be there when they try to plug into it.

On the "pot stirring" front, if we can't talk about removing cats (ie, threads deleted) because it's not legal, then why shouldn't this thread be deleted as well? Technically, any diesel swaps, or talk of them, are also really no different, from a legal standpoint, then removing cats; yet those threads remain????

SOHC to 5.0L swaps? Well, that's different. The 2nd gen Explorer came w/ a 5.0L as a factory option, so theoretically it would be a "legal" swap, in all 50 states (w/ varying "conditions", from state-to-state) However, a 4.9L was never a factory option on an Explorer, so it isn't a "legal" swap. Not to mention that you are going "backwards" putting an older engine/OBD1 into a later model vehicle/OBDII.

Hey, you wanted to "stir the pot"! Consider it stirred.

 

[Dan Whitaker]

Carguy so concealing the fact you removed the cats makes it o.k.?

 

[Glen4X4]

Leave it alone Carguy he wants to do the swap and is going to do it. It's his truck to whatever he wants with. No point in arguing about it.

 

[Turdle]

What is the intended use for the finished explorer?