May be dreaming, but future Expy project

[duranged03]

Have spent several hours reading and researching, I have a project in mind, that I may be flamed, banned, and hunted down for. May not get much help, but worth a shot. My 03 2wd, 4.sl0w sohc, I know what the main end result Im looking to do is, but unsure of several things still and some final pieces are undetermined.

I'm looking for external dimensions of the stock engines in the expy, V6 and V8, as the 4.0 will be replaced with a V8, but NOT the 4.6. I know a few have done the 4.6 swap and have had many obstacles and some havent finished the swap. I'm planning an even more challenging swap, I have patience and determination. Im pretty good with wiring, and have done several swaps and crossbreeds, but not where I needed to make totally different computer platforms interact and communicate properly.

Does anybody have dimensions of the trans tunnel and the factory trans external measurements? What about the rear diff and cv axles, what can be done or changed to make them reliably handle up to 450 ft/lbs torque? Just a good high number, dont know exactly what its going to push yet, but I have a goal.


Weight of the stock engines and trans? Fully dressed.

What all does the bcm control, and what all has to communicate with the ecu? I plan to install an aftermarket alarm/remote start system so not too concerned with all the extras like lighted keyless entry, etc. But if I can keep the bcm, and retain functions without the original ford ecu and mimic signals its looking for from another ecu than thats a plus. The gauges, Im thinking about going all aftermarket, The dummy gauges are definately not even a consideration for the build with the way Ford set them up to pretty much guess at settings and take readings in intervals instead of instant.

What It really comes down to, is, Id like to retain much of the vehicles factory function and appearence outside of the engine bay.

What about airbags and abs systems? Do they run off the bcm/ecm in any way or standalone systems? I also need it to be able to pass a state inspection for emissions, so other than being a newer engine and retaining emissions equipment, what else needs to be considered?

Anything else Im not listing that you can think of, feel free to post, its late and im tired and hadnt really planned on posting tonight. Other than posts telling me im dreaming too much or not to try it or it cant be done etc. I will make it happen one way or another, but thought maybe somebody here could help with some of the research anyway on sizes and weights, and wiring info. also if you can point me to some pinout diagrams or anything that would help.

I would also like to retain AC if possible, and if somebody wants to trade me for a V8 explorer I may just consider doing that right now lol. I know most people get the response, trade it in on a v8, I dont want to just trade it, I wanna build something totally off the wall and unsuspecting. I want somebody to pull up and think, hey, just another v8 explorer with exhaust..... Main point is, its mine, its paid for, its got problems, its got miles, i like the design (body, interior, and suspension designs), i like how its setup, i wanna build a toy.

 

[Kazer]

ls1 swap?

 

[Ronin8002]

Since you want it to be able to pass emissions, you may want to research into the emissions laws in your state and how engine swaps go into that. The law might allow for something simple like a carbureted setup and a distributor, so that would make the engine controls more straightforward. Otherwise for a fuel injected setup you would probably need to look into Megasquirt, SDS, or some other similar standalone fuel injection/engine management system.

I think the other electronics will probably be a challenge whether you go fuel injected or carburated though. I am pretty sure that at least the speedometer, fuel, water temp, etc, are tied into the vehicle's computer via the CAN bus (perhaps other things too), so you might find that you have to go with aftermarket mechanical or electrical guages for those and install compatible aftermarket sensors. The auto transmission controls are also tied into the computer. So I suspect you'll have to go to a mechanically (i.e. vacuum) controlled auto trans or maybe do a manual swap of some sort.

No idea on the power limits of the rear end but it is similar to the mustang cobra IRS. There is obviously a significant weight difference between an Explorer and a Mustang though so that may not be the greatest way to assume that the stock diff will hold up. You might just try running the stock one and see if it holds up. If it doesn't, then a solid axle swap in the rear with a leaf spring under axle setup would probably be feasible.

I think it could get expensive but if you put in the research and take your time with it, you could end up with a pretty awesome setup at the end.

 

[duranged03]

Actually..... close, 6.2L with 6L80E. Figured on aftermarket gauges, mostly because I dont like how inaccurate our factory gauges are. The 6L80E trans if Im understanding correctly, has its own computer built in, which will tie into the 6.2L ecu. Planning to keep all electronics of the engine, including all fuel injection, etc. I'm not really an auto trans person when it comes to building toys, but would with this Im going for something a little different, plus I dont wanna hack up the interior more than I need to, like gauges and such.

I've done a few similar swaps, efi into things that were never meant for it, big blocks into 4 cylinder vehicles, carb motors into efi cars, etc. But, dont wanna cut too much up or weld up a bunch of extra crap, basically I want this one to look more professional instead of thrown together and made work. Usually its just for the fun of doin it off the wall, go fast toys, or the mechanicals for other people and not getting past motor/trans swap cause they want to finish the vehicle theirself or they run out of money.

I want this one to be a driver, not just a weekend toy, I want it functional as an suv/people hauler without being over modified if you know what Im trying to say. The reliability, comfort, ride characteristics, etc. I want a sleeper, with exhaust. Something that if somebody got in and went for a ride, wouldnt suspect anything until the go pedal was tested. Yes Im sure somebody is going to say, "you can do all that with Ford parts" but unless your volunteering the parts or money then please dont post unless your offering information on what Im seeking. I dont plan to make an ass of myself on here about the swap, but figured it was a good source to get the answers for the first post.

Yes everybody does a chevy swap in their ford, and some people go the other way, Im going a slightly different route than usual, and Ford happens to offer more of what Im looking for in a midsize suv that anybody else, Just not engine-wise.

 

[Inspector13]

Personally I've never liked seeing chevy motors in fords and vice verse, but to each their own. The LSx series of motors (LQ is included) are great motors. My old silverado w/ 5.3 & 4L60E trans was great for towing (and embarrassing ricers). I'd check out an LSx website. Probably have quite a lot of the info that your looking for. Or a Chevy truck website. Helped me a lot with modding mine.

 

[duranged03]

I plan to gather what other information I need from ls1tech or other gm sites, I do have some experience with lsx, but dont think their sites would have much of the info Im seeking here.