How to: 4.2L V6 Mustang Engine Swap

[bucnknasty]

Im still having a few problems with the build. Ive been doing a little research and found an entire listing of ford motors rod length, stroke, and rod/stroke. according to this the rod length on both a 3.8 and a 4.2 are the same at 6.091. I have not purchased any 4.2 rods because i dont want to blow more money and be right back where i was. So with the rod length being the same on both a 4.2 and a 3.8, in order to build the 4.2 stroker, is the difference in the heigth of the pistons and not in the rods?


Here is the article where I found my info and the website
The Mayfield Company Homepage - Automotive Analyses

Table 1
Engine Parameters

Motor Year Stroke Rod Length Rod/Stroke
1.6L Kent 71-73 3.056 4.9280 1.6126
1.6L CVH 81-85 3.130 5.1945 1.6596
1.9L CVH 85-96 3.456 5.1945 1.5030
1.8L DOHC 91-93 3.350 5.2300 1.5612
2.0L OHC 97-98 3.465 5.1945 1.4991
2.0L OHC 71-74 3.029 4.9820 1.6448
2.0L OHC 83-87 3.126 5.2047 1.6650
2.0L ZETEC 95-96,98-00 3.465 5.3618 1.5474
2.0L ZETEC 97 3.465 5.482 1.582
2.2L Probe 88-92 3.700 6.2000 1.6757
2.3L OHC 74-94 3.126 5.2047 1.6650
2.5L OHC 98 3.401 5.457 1.6045
2.3L HSC 84-94 3.300 5.4570 1.6536
2.5L HSC 86-91 3.583 5.9900 1.6718
2.6L V-6 Duratec 95-97 3.1299 5.4370 1.7371
2.6L V-6 72-73 2.630 5.1400 1.9544
2.8L V-6 74-80 2.700 5.1400 1.9037
2.9L V-6 86-92 2.835 5.1400 1.8131
3.0L V-6 86-94 3.150 5.5315 1.7563
3.0L V-6 Duratec 97-00 3.1299 5.4370 1.7371
3.4L V-8 SHO 96 3.1299 5.4370 1.7371
3.8L V-6 82-94 3.390 5.9135 1.7444
3.8L V-6 97-00 3.390 6.091 1.7967
4.0L V-6 90-00 3.320 5.7480 1.7313
4.2L V-6 97-00 3.7400 6.091 1.6286
4.5L SVO ? 3.500 6.0880 1.7394
170 I-6 61-72 2.940 4.7150 1.6037
200 I-6 63-83 3.126 5.8800 1.8810
250 I-6 69-80 3.910 5.8800 1.5038
240 I-6 65-72 3.180 6.2097 1.9527
300 I-6 65-94 3.980 6.2097 1.5602
221 62-63 2.870 5.1550 1.7962
255 79-82 3.000 5.1550 1.7183
260 62-64 2.870 5.1550 1.7962
4.6L V-8 91-00 3.543 5.9331 1.6745
5.4L V-8 97-00 4.165 6.6575 1.5984
6.8L V-10 97-00 4.165 6.6573 1.5983
289 63-68 2.870 5.1550 1.7962
302 68-94 3.000 5.0900 1.6967
302 Boss 69-70 3.000 5.1550 1.7183
302 SVO ? 3.000 5.1550 1.7183
351W 69-96 3.500 5.9560 1.7017
351 SVO ? 3.500 5.9560 1.7017
351C SVO ? 3.500 5.7800 1.6514
351C Boss 70-74 3.500 5.7800 1.6514
351M 75-85 3.500 6.5800 1.8800
400 71-81 4.000 6.5800 1.6450
352 60-66 3.500 6.5400 1.8686
390 61-71 3.780 6.4890 1.7167
406 62-63 3.780 6.4890 1.7167
410 66-67 3.980 6.4890 1.6304
427 63-68 3.780 6.4890 1.7167
428 66-70 3.980 6.4890 1.6304
429 Std 68-73 3.590 6.6050 1.8398
429 CJ/SCJ 69-70 3.590 6.6050 1.8398
429 Boss (S) 69 3.590 6.5490 1.8242
429 Boss (T) 69-70 3.590 6.6050 1.8398
460/460 SVO 69-94 3.850 6.6050 1.7156
data from 1994 Ford Motorsport SVO Catalog and 2002 FRPP Catalog[/COLOR[/B][/I][/B][/COLOR][/COLOR]]

[lowflyn]

The 4.2 is a 3.8 block with a separate crank. I don't see the rod length being the same between a 3.8 and 4.2 crank...but honestly I'm not 100% sure.

I believe we're about to start on a split port 4.2 for the wife's 94 here in the next few weeks...so I'm sure I'll be going to this thread alot in the next few months.

[3.8boii]

k i have just bought a 4.2 and my question is will i use the front acesories from my stang like the pulleys and stuff

[bucnknasty]

Okay so I did find out the difference is in fact in the pistons. If you do a 4.2 crank swap you must use 4.2 pistons. But Now I have also ran into a few other problems as well. I have the block bored 30 over and cant seem to find any 30 over head gaskets. Do i need to use 30 over head gaskets and if so where can i find them? Also I am running a comp 200/208 cam with .480 lift. Will I need to swap out the stock springs for heavier ones?

[stephenmartin]

hey guys, im buying a 94 thungerbird for 150 bucks, it has the 3.8 in it, with the AOD tranny. im thinking on using it as a donor for my 97 stang, with a 95 3.8L harness, what i was thinking was using the 4.2L engine from my 97 f150 and dropping that in my mustang, and using the AOD tranny from the thunderbird. i dont plan on modifying the 4.2 in any way at all. i plan on cutting my hood up if i have to. my only question is.. should i just stick with the 3.8 from the tbird, and go back to what my original setup was, or go with the 4.2L? im scared of the 4.2 being junk and letting me down. just like my mustang 3.8 did to me (threw a rod and cooked the heads) plus the mustang AOD cracked the tailshaft and is missing 1st gear. whats your guys' opinion. i miss my baby!

[6ixer]

I read all of it but im confused
My dad has a 99 f150.
I have a cammed 3.8 and, the engine.kinda needs a.repair.
I was told to take the 4.2 strip it down.to the bare block id get it honed
Id take my 00, cly heads swap em over so id have the ac compressor and alternator in the org spot as the stang
can i use the f150 oil pan or my 00car pan
Will it bolt up to my 5 spd noproblem?
Plus hooking all the sensors back up....and the computer what about the.mustang top end...as in the mustand.upee intake and lower intake? No problem

[davidcseifert]

Originally Posted by 6ixer

I read all of it but im confused
My dad has a 99 f150.
I have a cammed 3.8 and, the engine.kinda needs a.repair.
I was told to take the 4.2 strip it down.to the bare block id get it honed
Id take my 00, cly heads swap em over so id have the ac compressor and alternator in the org spot as the stang
can i use the f150 oil pan or my 00car pan
Will it bolt up to my 5 spd noproblem?
Plus hooking all the sensors back up....and the computer what about the.mustang top end...as in the mustand.upee intake and lower intake? No problem

how many miles is on the 4.2 in his truck?
if you don't have anything done to your heads just swap your intakes and cam you can just reuse the heads from the truck (if it has lower miles than your car don't even pull the heads if you know it runs good saves you that cost)

it has literally the same block as yours the trans will fit just fine

this is on the first page btw...

- 4.2 shortblock or longblock
- You can use the 4.2 heads
- Mustang upper and lower intake and fuel rail
- Mustang 3.8 water pump
- Auto trans = 4.2 or 01-up flexplate
- 5spd = 01-up or rebalanced 3.8 (0 or neutral) flywheel and a pilot bearing
- V6 Mustang bellhousing
- Re-use your stock cam position sensor
- 01-up 3.8 oil pan
- 01-up 3.8 oil pick-up tube and screen
- 4.2 damper or 01-up 3.8 damper (use the 01 pulley for blower cars)
- Re-use the stock 3.8 oil pressure sender and tube
- Re-use the Mustang headers
- You can use the 4.2 or 3.8 dipstick. Just keep track of where 5 qts puts the mark when refilling with oil.

[xhgwx]

Originally Posted by davidcseifert

how many miles is on the 4.2 in his truck?
if you don't have anything done to your heads just swap your intakes and cam you can just reuse the heads from the truck (if it has lower miles than your car don't even pull the heads if you know it runs good saves you that cost)

it has literally the same block as yours the trans will fit just fine

this is on the first page btw...

- 4.2 shortblock or longblock
- You can use the 4.2 heads
- Mustang upper and lower intake and fuel rail
- Mustang 3.8 water pump
- Auto trans = 4.2 or 01-up flexplate
- 5spd = 01-up or rebalanced 3.8 (0 or neutral) flywheel and a pilot bearing
- V6 Mustang bellhousing
- Re-use your stock cam position sensor
- 01-up 3.8 oil pan
- 01-up 3.8 oil pick-up tube and screen
- 4.2 damper or 01-up 3.8 damper (use the 01 pulley for blower cars)
- Re-use the stock 3.8 oil pressure sender and tube
- Re-use the Mustang headers
- You can use the 4.2 or 3.8 dipstick. Just keep track of where 5 qts puts the mark when refilling with oil.

So the tranny will bolt up?

[davidcseifert]

Originally Posted by xhgwx

So the tranny will bolt up?

yes it bolts up just fine to any RWD application 3.8/4.2 block

[VPG]

Hello, I am new on here and not familiar with all the lingo yet, so if you could help me out..I have a 2003 V6 Mustang Coupe Base model with 64k and some change on her. My situation is two part: It has a light tapping noise when I go to 1800+rpm. I was told that the wrist pin is loose. Also told it could be carbon build up. The tapping only happens after ten minutes of driving, and sometimes difficult to detect. The garage said they could remove the oil pan for 500clams, I said I couldn't afford it so they used some tool to listen to it. My first car tech told me wrist pin also. Today, I put in a tank of midgrade from shell. I had been getting Conoco low end gas. Do you think this is what is causing the tapping? Or? Also I am considering replacing my 3.8 with a 4.2. After reading this, the re-man parts seem to be a good choice..? Is it possible to do this with my model stang? Yesterday I went to a dealership to see if I could just trade the car and they said my car had been wrecked and that there was frame damage and they cannot sell it. I was sold the car years ago, with a clean Carfax, so I am trying to figure out what to do on that. So, I must keep her. That is just fine, I love my car, and I want to keep her going. Any convo on this is great, I really appreciate it! ~V~

[SN95V600]

dam they ****ed u thats bs man how is it clean carfax yet it has frame damage for all u know they are bs u becuz they dnt wana trade u and give u something else dnt listen to them man tell them they better or there will b problems dnt let them play u man

---------- Post added at 08:55 AM ---------- Previous post was at 08:54 AM ----------

it tends to sound like a piston slap or push rod but better off getting another engine it could just be spark knock

[davidcseifert]

Originally Posted by VPG

Hello, I am new on here and not familiar with all the lingo yet, so if you could help me out..I have a 2003 V6 Mustang Coupe Base model with 64k and some change on her. My situation is two part: It has a light tapping noise when I go to 1800+rpm. I was told that the wrist pin is loose. Also told it could be carbon build up. The tapping only happens after ten minutes of driving, and sometimes difficult to detect. The garage said they could remove the oil pan for 500clams, I said I couldn't afford it so they used some tool to listen to it. My first car tech told me wrist pin also. Today, I put in a tank of midgrade from shell. I had been getting Conoco low end gas. Do you think this is what is causing the tapping? Or? Also I am considering replacing my 3.8 with a 4.2. After reading this, the re-man parts seem to be a good choice..? Is it possible to do this with my model stang? Yesterday I went to a dealership to see if I could just trade the car and they said my car had been wrecked and that there was frame damage and they cannot sell it. I was sold the car years ago, with a clean Carfax, so I am trying to figure out what to do on that. So, I must keep her. That is just fine, I love my car, and I want to keep her going. Any convo on this is great, I really appreciate it! ~V~

easy way to tell if it's carbon build up throw premium fuel in it (or even midgrade sometimes if it's minimal buildup) if the sound doesn't go away try a higher grade if it still doesn't it's a mechanical issue

as far as the 4.2 swap yes you have the correct year range car to basically just swap over your stuff for it, find the lowest miles motor you can

as to the dealership problem ask them to show you the proof of the wreck.. or check carfax yourself sounds extremely messed up

[superpkjoe]

this is what i was looking for

[superpkjoe]

i want to drop a 4.2 in my stang cuz i have over heat the 3.8 2 times now an well i blow a manifold this week so i got headers an i am going to install them but when i tuke a sparkplug out alot of water came out so i now that that engine is trash so i want to drop a 4.2 on it i now i have to change the upper an lower intake from my 3.8 an it sude dropp right in to place so will every thing else be the same its an automatic will the ac an the rest pdd the pulles be the same ?

---------- Post added at 01:14 PM ---------- Previous post was at 01:13 PM ----------

can any one help me out an just give me a opinion

---------- Post added at 01:16 PM ---------- Previous post was at 01:14 PM ----------

love my car but want more power an well i have heard of people dropping a 4.2 on there stang befor as well so i want to do the same as well i got alot off good info from all you guys stuff you have posted an what i have read here

---------- Post added at 01:20 PM ---------- Previous post was at 01:16 PM ----------

i got some stuff i have done to it like doul muffeles 10.2 mm spark plug wires coil pack cold air trottle body spacer an now headers so i want to move to alot more power so i want to drop a 4.2 in it now an well i have a posi read end on it that i installed as well so it really dose go well that was befor i over heat it do still runs but i have to look at the temp all the time an put water cuz it dose not last long on there so plz some one help

[davidcseifert]

you just have to swap over the parts listed on the first page according to the year of your car whether you buy or swap them, as to the assec on the front of the motor if you can, swap yours over since you know they work, as far as i know they should be the same aside from the water pump which has a fan on it in the trucks just have to do a little investigating if something doesn't look the same between them

this would also be a good time to look into a windstar intake swap for a little more oomph to it

[superpkjoe]

oh (0o) cool i get it i am still not going to do it any time soon i will do it in like the begining of next year or so. i am also going to install a 3 row radiator all aluminum whit duel fans an also need a trans cooler on it an well i will beef up my trans as well whit a shift kit an toque converder to really make it go fast. so if i get a windstar intake what is the diffrence on it do ?

---------- Post added at 09:49 PM ---------- Previous post was at 09:46 PM ----------

wow bro men you really made that bad boy fast men god that is sweet

---------- Post added at 09:53 PM ---------- Previous post was at 09:49 PM ----------

were did you get your heads for your v6 stang men i have been looking an never found anything like that or a cam for that meter the only one that has one is oreilly auto parts an

[davidcseifert]

Originally Posted by superpkjoe

oh (0o) cool i get it i am still not going to do it any time soon i will do it in like the begining of next year or so. i am also going to install a 3 row radiator all aluminum whit duel fans an also need a trans cooler on it an well i will beef up my trans as well whit a shift kit an toque converder to really make it go fast. so if i get a windstar intake what is the diffrence on it do ?

---------- Post added at 09:49 PM ---------- Previous post was at 09:46 PM ----------

wow bro men you really made that bad boy fast men god that is sweet

---------- Post added at 09:53 PM ---------- Previous post was at 09:49 PM ----------

were did you get your heads for your v6 stang men i have been looking an never found anything like that or a cam for that meter the only one that has one is oreilly auto parts an

You'll need a little bit of tuning or a stall otherwise the car will slip/not act right under accel, been there lol

The Windstar has longer long runners and shorter short runners, meaning it will increase greatly throughout the rpm range and a little more in the too rpms, I have a dyno chart ill upload later

And thank you, the current ones are SuperSixMotorsports, but the new better ones going on are from www.kylepersonperfromance.webs.com

He can sell you basically anything you need motor wise for our sixers, he does very good work and makes some nasty cams

[superpkjoe]

oh yeah cool bro love the info men god i love it going to make that babe fast now

---------- Post added at 09:51 PM ---------- Previous post was at 09:49 PM ----------

oh an were can i get a stall converder for the stang

[superpkjoe]

is there a special brand i sude get
an the web page that you posted for the cam an mod stuff dose not work

---------- Post added at 10:06 PM ---------- Previous post was at 10:04 PM ----------

an do you now were i can get parts to rebilt my trans whit really good performance parts like good cluches an stuff

[davidcseifert]

Originally Posted by superpkjoe

oh yeah cool bro love the info men god i love it going to make that babe fast now

oh an were can i get a stall converder for the stang

Originally Posted by superpkjoe

is there a special brand i sude get
an the web page that you posted for the cam an mod stuff dose not work

an do you now were i can get parts to rebilt my trans whit really good performance parts like good cluches an stuff

sorry i typed the link instead of C&P, got it mixed up here this works
Home - Kyle Person Performance

as for the converter, i have this one in my car
AODE 4R70W Stage 3 Torque Converter

call around local transmission shops and see who can do what you need, but is it acting up? i still have my factory 140K automatic in mine without any problems

[superpkjoe]

cool bro no my trans its good right now but if i am going to drop a 4.2 on it an need a torque converter to really make it fly well i might just rebild it to take it cuz my stang has 189xxx miles on it aqn well i dog the snot out of it all the time even whit the bad head i dog it hell i still smoke rsx acuras an civics an sentras all day long you now what i mean i been trying to make the engine blow for the longest now. At this point i dont really now it's still running its a tuff engine i tell you. i had imports that i destroy the engine on cuz they suk an this babe is been running like this for about over a year now an still drives fast but i have really bad gas miles on it do.

[superpkjoe]

oh an by any chance i can see a pic off the windstar intake you installed in your mustang cuz there are alot off them out there an well i wood like to see how it looks in the mustang an how it all goes together whit the trottle body an everything else that goes whit it like the fuel rail did you still use the mustang one ?

[superpkjoe]

ok bro i think i now ]which intake you was talking about i am going to go get one http://kylepersonperformance.webs.com/winnie_engine.jpg

[SN95V600]

So this 4.2....can i use the ssm lumpy cam in it?

[davidcseifert]

Originally Posted by SN95V600

So this 4.2....can i use the ssm lumpy cam in it?

Of course