Blown engine- Transplant from Aerostar?

[Dodger_me]

Hey everybody,
So About a month ago i blew the engine in my 95 Limited.
Pulled the engine, and it turned out i bent a connecting rod(I hydro locked it) and the piston skirt was jammed into the crank

I dont really feel like rebuilding this engine as god knows what else happened when i hydro locked it, So at the moment im looking at buying a 96 Aerostar to rob an engine from. (Found one with the back all smashed in and written off) Also the owner confirmed it is a 4.0L V6

The aero star im looking at is awd and from what I have researched the awd version comes with the same 4r44e as my explorer, So i should be able to swap the engine and transmission(I had to pull the torque converter out of the trans as my engine was seized and i hear its almost impossible to reseat a TC) in without any issues right?


Has anyone ever done this swap before? Planning on starting this weekend and just want to get some insight.

Thanks people!

 

[BrooklynBay]

I've moved your thread into the Aerostar section. Both vehicle have the same 4.0L engine & 4R55E transmission. Take some pictures when you make the swap, and post them here.

 

[kevinsranger]

it would be very hard to unbolt your tc off the back of your flywheel without rotating the engine, i suppose you can get a wrench in there possibly, but better off getting the tc off the donor and saving the work

 

[Dodger_me]

well i already have my engine out and the transmission off(put it in my engine stand to determine damage)

I was thinking i would just take the whole engine, trans, tc assembly from the aerostar and put it in

 

[BrooklynBay]

Don't forget to flush out the front transmission cooler with cooler cleaner before the transmission is installed. Now is a good time to install an external transmission filter with a temperature gauge.

 

[Dodger_me]

Can i just use normal tranny fluid?

I wont worry about the external filter, Im planning on selling it soon so i dont really want to dump too much money into it.

 

[BrooklynBay]

You could use regular transmission fluid with an air compressor, and a container to catch the fluid.

 

[FORDBOYpete]

Dodger FYI

Dodger,
I concur with your 2nd post of thread where you want to swap entire power train without separating it (ie: Engine & transmission as 1 unit). I do it that way in defference to splitting assemblies unneccessarily. By using a complete assembly you reduce potential problems, need to replace seals, time of job & chance of errors. It just makes good sense to me, if there is no reason to separate Engines from Transmissions, not to do it.


Before you scrap the Hydra-locked 4.0L you might want to pull your upper & lower intake manifold set off and see if gasket surfaces where lower manifold mates against heads is clean, or if's erroded. Clean lower intakes are getting hard to come by in used condition.

Also use all OBD-1 sensors from your siezed engine as you already know they are correct for ECM & Op' system modules in your Aerostar. Seems a slightest difference between sensors & modules/ ECMs create nightmares you neither want nor need. I learned that lesson a hard way. Also that's why FoMoCo Dealers, Better Repair Shops & Informed Techs, reference vehicle VINs when ordering & getting replacement parts for their FOMoCo vehicles Op' Sys's.

Other than these few items you virtually have a "bolt in" deal before you. Good Luck on your project.

CIAO

FBp

 

[Dodger_me]

Thanks for all the help guys
Unfortunately I couldnt get my friends flatbed this weekend, Hopefully I'll get it this weekend and will finally have a vehicle after two months of busing to school...

So basically the safest route will be to pull engine and trans, Swap over all my sensors(Injectors too?) to the new engine right?
Are all the connectors the same or will I need my old engine harness?

 

[BrooklynBay]

Try to transfer as much as possible.

 

[FORDBOYpete]

If it's not broken don't fix it. . . .

Dodger,
IMHO I would not necessarily replace old injectors with used injectors because it's a major task on the 4.0L Cologne Engine. It req's removing upper intake manifold & all it's related component parts.

It's a lot of work for a chancey /iffy deal for questionable gain. I personally do not R&R stuff unless I identify a specific problem(s).
On other hand, I change components off "take out engines" which are new or recently replaced. Sensors, switches, coil pack, wires etc. the easy stuff are all a good bet. If engine you got has a injector problem it's not necessarily an injector itself, could be in wiring, or Ign Coil Pack or worse ? ? ?
Again this's is just my opinion & it's from experience, not laziness.
CIAO
FBp

 

[tuckman]

I agree with the last post. After fighting with leaking injector o-rings for a couple weeks, you will be much better off just leaving them be. I have gotten very good at taking off the upper intake manifold and fuel rail, I only did it 5 times in 2 weeks!

 

[FORDBOYpete]

Hey Tuckman, LOL ;-)
Isn't experience an excellent teacher on what not to do if you do not necessarily need to do it?

 

[tuckman]

No kidding!

 

[john-john]

I don't mean to resurrect an old thread but.. what codes does the 'star spit if the injector o-rings leak. i have a right bank lean code on my 97 and i'm going to do the intake gasket swap anyway. It's from arizona so most of the rubber is way worse off than it's canadian peers.

 

[BrooklynBay]

Welcome to this forum! Leaking injectors will show a rich code since excessive fuel goes into the engine. It might smell & behave like it's flooded.

 

[john-john]

uhm.. sorta..

Welcome to this forum! Leaking injectors will show a rich code since excessive fuel goes into the engine. It might smell & behave like it's flooded.

the injector o-rings are on each end of them... not inside.

so, if they leak they'll leak fuel on the intake, or vacuum into the port..

 

[john-john]

and for your swap. the 96 'star used the 90-94 'sploder heads marked with a "T" on the exhaust port. I think your 95 used a "U". so i think the heads and pistons are different. there is a warning on the 4.0 rebuild tech article about mis-matching engines to PCMs. it'll bolt up but burn down in 10,000 miles.

(if i recall correctly...)

 

[FORDBOYpete]

HMMMmmmnnn ! ! !


john - john,
ThanX for resurrecting the thread & Thanx for bit of info on 4.0L heads. It's good to Know.

Do You know anyone using a 4.0L Cologne in a Marine App' ? I'm curious about doing that. Got Que's about Jet vs Prop drives too.

I've a few 4.0L's 1993-1995 Vintage, stuff all Aero' based engines. Never paid attention to subtle differences. I've not had to, Yet.

CIAO
FBp