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I have a 91 2door explorer with a 4.0 v6 that locked up. Will a 2004 explorer 4.0 motor bolt right in without major mods?
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It'll be a big job. For one thing the 2004 engine is OBD-II and so you'll need to swap over all the sensors, wiring harness, ECU, and probably instrument cluster, fuel pump, tank, and transmission etc. as well.
I think by 2004, they were all SOHC which makes it MUCH more difficult. If you found a newer OHV, you could strip it down to the long block and drop it right in.