02' 3.8L in a 98 3.8L body? - Mustang Evolution

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Old 07-28-2014, 08:02 PM   #1
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02' 3.8L in a 98 3.8L body?

Ok so I have a 1998 v6 3.8L mustang with a blown engine, my dad and I are planning on swapping it out. I found a 3.8L engine out of a 2002 mustang in great shape for a good price. I was wondering what exactly I would have to change to make the 02 engine work in my 98.

For the people who are wondering...
Why not v8 swap?
Don't have the time or money at the moment
Why not get a 3.8L out of a 97 or 98?
Most 99+ 3.8Ls are cheaper and in better shape than the 97&98 3.8Ls. Also they have the split port and offer about 40hp more than the 98.

I know it can be done, just want to know how difficult it will be.
If anyone has done this and know what needs to change in the 98 to fit the 02 engine it would be appreciated if you could help me out. Btw I am asking if I can swap the entire 02' engine and what parts from the 02' car I would need to make it work. The guy selling the engine is doing a V8 swap and said he is willing to sell all parts I need to make the engine work. I do not want to do a split port swap combining parts from the 02' engine and 98 engine.
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Old 07-28-2014, 11:10 PM   #2
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What are the differences between single port and split port?

To start we will discuss the differences between the 3.8 v6 motors. The 94-98 v6's are equipped with single port heads, lower intake, and upper intake; these have one intake runner per cylinder. On the 99-04 v6's, Ford switched to a split port design, which has two runners per cylinder.

From the factory, the split port design gave the v6 an additional 40hp, so some people with 94-98's like to swap their singleport heads and intakes for the split port. Doing this is a very custom setup, and there are some modifications that will need to be made. I will discuss these later.

What parts are needed for a split port swap?

Here is to the best of my knowledge a complete list of parts needed for a split port swap:

heres the parts list:
-97+ f-150 V6 heads or 99+ mustang v6 heads (including valves/springs)
-97+ f-150 v6 lower intake, or 99+ v6 mustang lower intake *
-99+ mustang v6 upper intake **
-99+ mustang EGR tube and valve (f-150 tube will work)
-99+ Throttle Body
-TPS sensor for TB (1-CX-1488 from Ford) if not already on TB
-Throttle cable from 99+ mustang v6
-99-04 Windstar fuel rail
-Accelerator Bracket (F4SZ-9728-B) if not already included on upper intake
-99+ mustang v6 coil pack and wires (your stock coil pack will work too)
-99+ mustang intake tube, or any 99+ mustang CAI kit
-99+ mustang cooling hoses (including the ones going to the heater core) and pipes. You can also make your own lines, by using plumbing elbows,hoses and clamps, and fab it up yourself. (Definately get these if you can.)
-16 a.w.g automotive electrical wire
-teflon tape, pipe sealant, RTV
-99+ head bolts/studs
-head gaskets (I recommend 99+ mustang gaskets)
-99+ upper and lower intake manifold gaskets.
-99+TB gasket
-94-98 IAC gasket
-94-98 valve cover gaskets(reuse the 94-98 valve covers, valve cover gaskets can be reused if removed carefully)
-94-98 exhaust header/manifold gaskets
-you can reuse the 94-98 headers ****
-use the 94-98 IAC since the 99+ IAC has a different connector (Edit: I found that the IAC I used from a 99 mustang had the SAME connector. I am not sure about other years or F150's/windstarts, but the 99 IAC will work and I recommend using it for a cleaner looking install.)
-rad fluid, oil, filter, new spark plugs
-gasket remover, thinner to prep parts before applying new gaskets

* There are 3 different types of lower intakes you could use; these would be the 97+ F150 lower, the 99-00 lower, and the 01-04 lower. Each has its ups and downs, but I would recommend going with a 99-00 lower. Here are the differences:
The F150 and 01-04 lowers have IMRC's in the lower intake which will need to be removed, and the holes JB welded shut since the 94-98 ECU's don't have the ability to control these. The 99-00 lowers don't have these, and therefor you will have no modding to do.
The 94-98 lowers have 2 water temp sensors that go into the lower intake. The F150 lower also has 2 locations for these sensors on the lower, no problem there. The 99-04 lowers only have one water temp sensor and will need to be modified to work. You can do this by drilling/tapping a hole for another sensor in the lower before it's put on. There is a good spot for doing this and I will try to get pics later. Any machine shop could do this, and others have had it done for $5-10.
If you use an F150 lower, you will need to run custom cooling hoses. The F150 hoses won't work, and the 99-04 mustang cooling hoses won't work with the F150 lower. If you are using the 99-04 lower, the cooling hoses will fit and work fine.
My personal opinion would be to use a 99-00 lower, but all will work with some modification.
**There is a slight difference between the 99-00 upper intake and the 01-04 upper intake. The 99-00 upper has 4 holes for the coil pack to be mounted, vs. only 3 on the 01-04. If you can get the 99-00 upper it will be easier to mount your stock coil pack.
***The 94-98 mustangs use a return style fuel system, and the 99-04's use a returnless style. Therefor the 99+ fuel rail will need to be modified with a return fuel line. As noted above, SteveC on this board is again offering to make custom fuel rails for split port swaps.
****You can reuse the 94-98 headers, but you may run into trouble with hooking up the egr tube. I believe it mounts into a different location on the 99+ exhaust manifold and may not fit. You would need to have this customized to fit, or to use the 99+ exhaust manifolds/gaskets. I am not certain as I deleted the egr when I did my swap.

How difficult is it to do a split port swap?

A good bit of mechanical ability is needed to do this. If you don't usually work on your own car, this is not a good place to start learning. On a difficulty level of 1-10, I would rate this about a 6.5. You will be going pretty deep into your engine, and because it is a custom setup it can be tricky. From start to stop, this project took me about 3 full days of working (by myself though, extra hands would've helped at many points) plus driving to get odds and ends I didn't account for.

You will need basic tools such as metric and standard socket sets, swivel joints, extensions, wrenches, screwdrivers, a torque wrench in ft/lbs, (also a smaller torque wrench in inch/lbs is helpful but not necessary), wire cutters, butt connectors for the wires or a soldering gun, and plenty of patience. You will also need special tools for removing the fuel lines from the stock fuel rail. (AutoZone should have these)

There is also a video made by V6Sprout from v6power.net that is a step by step guide to doing the split port swap. It is very helpful and I would recommend it to anyone doing the swap or even considering it. Watching the video could help you determine if you think you can do the swap yourself or not. (I no longer have or sell copies of the tapes. The copies were not turning out good and I sold my original copy to someone else.)
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new engine,1.7 rocker arms,Pipes exhaust, shorty cats , shorty headers,under drive and overdrive pulleys,4.2 upper plenum, throttle body spacer, cold air intake, stage one clutch, shorty shifter, and tune. 8.8 in storage
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Old 08-01-2014, 10:58 PM   #3
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He doesn't want to do a split port swap. He's switching the entire engine.

You need the computer along with the engine. I'm not sure Into the specifics on it but the 02 engine will drop right into the 98.

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Old 08-05-2014, 07:28 PM   #4
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If you switch the entire engine you are basically doing a split port swap and should know out of this part list what you need and do not need. For example: you would need a newer throttle cable. The newer computer is not needed unless you change the fuel injection system to non return.
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new engine,1.7 rocker arms,Pipes exhaust, shorty cats , shorty headers,under drive and overdrive pulleys,4.2 upper plenum, throttle body spacer, cold air intake, stage one clutch, shorty shifter, and tune. 8.8 in storage
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Old 01-31-2015, 07:42 PM   #5
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Basically you need the entire drivetrain set up minus tranny driveshaft and rear end and you need the whole computer and wiring along with entire engine. You may need an adapter plate and a few other things to hook the engine up to the tranny


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Old 02-14-2015, 02:11 AM   #6
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Quote:
Originally Posted by tsteevs_foxbody View Post
Basically you need the entire drivetrain set up minus tranny driveshaft and rear end and you need the whole computer and wiring along with entire engine. You may need an adapter plate and a few other things to hook the engine up to the tranny


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1. Are u kidding me every 3.8 ford made has the same tranny bolt pattern!!
2. Go to painless wiring and get the adapter made for $30 to go from 98->02.
The only thing u might need is the to complete swap will be throttle cabling if all the sensors and stuff still work. Then have a tune done so the ECU of ur existing car will compensate for the bigger injectors of the new motor! Or just swap ECU's (engine computer). This swap is pretty straight fwd as they are the exact same motor aside from the split port heads and intake!!!


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Old 10-18-2015, 03:42 PM   #7
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Quote:
Originally Posted by Jmustang78 View Post
1. Are u kidding me every 3.8 ford made has the same tranny bolt pattern!!
2. Go to painless wiring and get the adapter made for $30 to go from 98->02.
The only thing u might need is the to complete swap will be throttle cabling if all the sensors and stuff still work. Then have a tune done so the ECU of ur existing car will compensate for the bigger injectors of the new motor! Or just swap ECU's (engine computer). This swap is pretty straight fwd as they are the exact same motor aside from the split port heads and intake!!!


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I am doing the same swap in my 98 but I am using an 04 motor and tranny. Do you have the model number for the painless wiring kit?
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Old 11-08-2015, 08:20 AM   #8
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Off the top of my head I don't had to sell that car 😒 but I got my other mustang I'm doin a 5.4 or v10 swap into 😏


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