Will a 96 4.0 work in my 94?

[SScott]

What would I need to do to make it work? I ruined my engine going diving and am on the hunt for an economical solution. I found a 96 Vin X 8th digit and would be very thankful if you guys could tell me if it will go right in.

Thanks, Scott

 

[corkey]

it won't go right in, there are things you have to change to make it work,
some of the sensors are different and the intake and exhaust are not the same,

 

[Anime]

The motor will fit in since the block and lots of other stuff is the same, but a lot of other stuff changed from 94 to 95 when they went from a TTB front suspension to IFS. The electronics and all that is different as well.

If you swap it in, you can make it work if you take what you need from the 94 engine:

I do these conversions alot, each one is a little different then the last

when dealing with the OHV 4.0L 96 into a 94 just:

remove 94 engine and park it

park the new 96 engine NEXT TO IT
strip the 96 down to the lower intake and valve covers

the 96 MAY or MAY NOT have an 8 bolt crank, so look at the backs of your engines
lets say your 96 came from a 5 speed and the 94 is an auto, you would need to go buy a 96 style (8 bolt) flexplate, bolts, and spacer

If the 96 came from an auto and the 94 is an auto, you are golden, 96 already has a flexplate

belive it or not there are hardly ANY CHANGES from 94-96 aside from OBD-II computer, plastic upper intake and the OIL PAN

Compare the two engines side by side, see the oil pan differences?
Do the 96 engine mount plates look identical to 94? if so you can use them
oil dipstick? exhaust manifolds?

You will want the 94 oil pan and pickup tube,you will need a new gasket for this swap, I believe the 94 pickup tube will bolt to the 96 oil pump, so no need to buy new if the 96 oil pump looks good

once the 96 is fitted with the 94 mounts and oil pan you can drop it in the truck and stab it to the transmission

Now start fitting your 96 block with ALL THE PARTS from your 94 engine, fuel rail, upper intake, accessories, exhaust manifolds, egr, everything

here are the differences between a 96 OHV and a 94 OHV:

-oil pan for 96 is shaped to clear IFS/Gen II truck
-mid year 96 or so all OHV got an 8 bolt crank, 91-95 is 5 bolt
- plastic upper intake
-the CAMSHAFT POSITION SENSOR IS DIFFERENT DEPTH, you are going to HAVE TO USE your 96 cam sensor because the 94 will not fit in your block! the 96 sensor MAY have 2 wires, the 94 may have 3, if this is the case, I can help you wire the 96 sensor to your 94 truck, it will work I have done it many times

Thats it! all you want from the 96 truck is the block and heads really

IN this thread I put a 96 Ranger 5 speed engine into a 95 automatic truck:

http://www.explorerforum.com/forums/showthread.php?t=151705

that will help you with the cam sensor and crank bolt pattern issues

the OHV engine itself changed VERY LITTLE from 1991 to 2001 believe it or not, its all the stuff that bolts to it that changed, and that didnt change much either

with your conversion, if you wish, you can likely use the 96 plastic intake, the fuel rail and injectors, and many accessories, just use the sensors from the 94 block, the big change is the plastic EGR to intake setup thingy