OK... back at the swap (I have been doing a lot of side jobs for folks and money comes before fun). Anyway, I just want to document a few needed changes for everything to hook up like the stock 4.6 did before I forget them.
1. Need to make a 5.4 intake to 4.6 TB adapter (Done). This is due to my 4.6 being drive-by-wire and the 5.4 using a throttle cable. If the 5.4 were drive by wire I think that you could just use the 5.4 TB. The only thing I don't know is if the 1" tall adapter I made is going to cause the setup to hood when closed (although I don't think so). If someone wanted to measure how much clearance they have between the top of the TB and the hood when it is closed I would appreciate it (not sure how you would do it though
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As a side note, does anyone have wiring diagrams for the engine wiring harnesses? It would be helpful in making sure I have all connectors where they are supposed to be when I swap the 4.6 harness over to the 5.4 later today or tomorrow.
2. Swap Motor mounts from the 4.6 to the 5.4
3. Use the 4.6 exhaust manifolds (so that heat crossover tube is on the correct side)
4. Swap all coolant/related tubes and brackets from the 4.6 over to the 5.4 (so that there is no need to fab/splice tubes to hook everything up) I will take pics of these pieces later on so that you understand.
5. Use the 5.4 intake (due to head spacing)
6. 5.4 has one knock sensor, 4.6 has 2. (no big deal, I will explain after I have everything hooked up and running so that I make sure that my solution works).
7. There will be some minor exhaust fab work to hook up the stock exhaust due to the heads being slightly wider on the 5.4 (from what I understand it's pretty simple, I will post pics when I get mine done).
8. Swap the oil filter adapter from the 4.6 to the 5.4 (different design)
9. Possibly have to shim/space the flexplate to torque converter. The 5.4 is an 8 bolt crank, the 4.6 is a 6 bolt crank, and the flexplate is different. I have measured a few times and it looks like the distance is the same between the block and mounting holes on the flexplate (at least on my 04 4.6 and 02 5.4). If this is true than nothing needs to be done...! I will update when I joint the engine and trans together and measure...
I'm sure there will be a few other things, but it still looks like it's going to be relatively straightforward. When I am done I will submit lots of pics and if someone wants to work with me on a write-up I will be more than happy to help so that we FINALLY have a step by step on this swap.