Starting my 4.6 to 5.4 prep and swap! - Mustang Evolution

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Old 09-08-2011, 04:34 PM   #1
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Starting my 4.6 to 5.4 prep and swap!

Hello everyone! So I had a post before with some pics of the day I bought the engine, but now we have just moved into our new home, and I have the garage all to myself! So this weekend I am getting the boxes broken down, and moving some stuff around, then its time finally!

The car is a 98 GT, has some little things done to it. Me and my girl purchased it for sentimental reasons, it had a spun bearing or something on the bottom end was broken, and I promptly blew the engine. As I'm a "Honda guy" I was a little disappointed when we got it, that my motored civic hatch was stronger and faster. I have come up, to fear the mighty mustang. So I was thinking big mods, the day I bought the car.

I met a guy, who laid out to me the 5.4 swap... 6 weeks later I got one from a 2001 Expedition. And now a month later I'm ready to clean it off! I have a 5 gallon bucket of dawn, brushes, degreaser, all the holes taped with electrical tape, ready to go.

So far the 2 things I know I'm missing is the proper flywheel to use, and to decide how to go with the intake manifold. I will put some pics up as I go.

This should be fun!
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Old 09-08-2011, 04:37 PM   #2
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Here's what I'm working with!
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Old 09-08-2011, 05:02 PM   #3
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Quote:
Originally Posted by Scarreddragon
Here's what I'm working with!
Do a lightning swap!
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Old 09-08-2011, 05:57 PM   #4
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Lol. I don't have that kinda money. Plans are to do the motor, dyno-tune it right, drive it and tighten up the car as needed, and if I need more, NOS. This is going to be a true daily driver.
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Old 09-08-2011, 05:59 PM   #5
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"The Growler"
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Old 09-08-2011, 06:10 PM   #6
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I've thought about doing this same swap. I have a expedition engine here at the house but I wasn't sure how much of a pain it would be or if it would fit right in or even how much more power I would get.
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Old 09-08-2011, 06:43 PM   #7
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I would not even be doing this if it was not so easy. It is about 15% more hassle than a straight 4.6 replacement. I think the hardest part of this whole thing is the debate between the "adapter plate" setup, and the "hps highballr" setup. 200-300 bucks for the plates, 600-750 for the full manifold.

The adapters, raise the 4.6 manifold up, and the negative of this it does not allow good spray from the injectors. Hence worse gas mileage, and not the best for power, although not really a loss in power from stock numbers if tuned right.

The highballr, is a 15-30 HP increase, it keeps the injector where it should be, and also allows the tune to make power lower in revs.

If you have a running/blown 4.6 already in the car, you have 95% of what you need... Supposedly. Lol. I'll let you know.

Numbers, go like this:
215 HP / 285 tq stock 98 GT.
260 HP / 350 tq stock 01 expedition.

That is pretty good for increases, considering I paid $426 for that much power and torque. The Growler has no cats, a X pipe, and cherry bomb exhaust. A cold air intake up front too. If I spend the money on the highballr people are telling me 325 HP and over 400 tq is very possible at the ground!

That's enough to have fun!
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Old 09-08-2011, 07:28 PM   #8
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What about engine mounts? Do the same ones off the 4.6 work? Sounds like a fun project.

---------- Post added at 07:28 PM ---------- Previous post was at 07:27 PM ----------

And the gt computer will work?
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Old 09-08-2011, 08:04 PM   #9
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Engine mounts are same! Computer works.. but NEEDS to be tuned on a dyno, or traded for a mail-order pre programmed ecu. Basically the ecu needs to know about the extra .8 liters.
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Old 09-08-2011, 11:31 PM   #10
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Cool. I'm gona really think about doing this. Thanks!

---------- Post added at 11:31 PM ---------- Previous post was at 11:29 PM ----------

& what about the coils because doesn't the 5.4 have individual coils?
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Old 09-09-2011, 01:25 AM   #11
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Almost all new ford engines got the same mount except the 4 n 6 cylinder
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Old 09-09-2011, 09:12 AM   #12
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This is what I know about coils, there are 4 5.4's, the cobra 4v supercharged, the lightening 4v sc, the 96-00 3v?, and the 2001-2007 2v. The last one is the most direct swap. All others (anything not 2 valve) needs a lot more work, but its all electrical differences.
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Old 09-09-2011, 10:19 AM   #13
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The lightning with The supercharger is a 2v and it's pretty much a direct swap
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Old 09-09-2011, 12:10 PM   #14
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Quote:
Originally Posted by bobsurvives
The lightning with The supercharger is a 2v and it's pretty much a direct swap
+1

---------- Post added at 12:08 PM ---------- Previous post was at 12:07 PM ----------

Shelby is a 4v 5.4

---------- Post added at 12:10 PM ---------- Previous post was at 12:08 PM ----------

Quote:
Originally Posted by Drodriguez2009

+1

---------- Post added at 12:08 PM ---------- Previous post was at 12:07 PM ----------

Shelby is a 4v 5.4
96-04= 2v or 4v 05-09?= 3v or 4v 10-11= 4v?
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Old 09-09-2011, 01:00 PM   #15
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Thank you for correcting me. I'm still trying to take it all in.. I have a 2v right?
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Old 09-09-2011, 01:45 PM   #16
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Thank you for correcting me. I'm still trying to take it all in.. I have a 2v right?
Yup the navigator has a 4v
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Old 09-10-2011, 03:13 PM   #17
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96-04 gt's are 2v. 05-09 gt's are 3v. 03-04 cobras and Mach 1's are 4v. And these are all 4.6l. The 05-09 gt500 are 5.4l 4v.
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Old 09-10-2011, 03:25 PM   #18
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How would you but a gt engine?
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Old 09-10-2011, 03:36 PM   #19
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Buy one? At a junkyard. What kind matches it I have no idea. There were no GT's the day I went but there was a 02 F150 had a 4.6 in it. I wasn't there for a GT motor...
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Old 09-10-2011, 07:51 PM   #20
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Buy one? At a junkyard. What kind matches it I have no idea. There were no GT's the day I went but there was a 02 F150 had a 4.6 in it. I wasn't there for a GT motor...
Not mustang gt
Ford GT
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Old 09-16-2011, 11:55 PM   #21
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So, I need to go to auto zone to purchase this flywheel we need. I'm told I need a 8 bolt, 10.5 inCCG one. Does anyone happen to know what make and model would use that to help me get through the parts store computer?
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Old 10-02-2011, 11:08 AM   #22
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So, we got the start we wanted. After cleaning it I removed the tape and found debris in the intake ports. Today we ate going to remove the heads and clean it out. I have some experienced help coming so I won't have to time the motor.

I really need your guys help now though. I need to buy valve covers, and an oil pan. I would like to get a moroso pan for sure, but I don't know how to identify my motor properly to order one from summit. Valve covers are the same issue. What do you guys think? Can someone point me in the right direction?

Will the mustang valve covers work? Is rather have something shiny but saving money for the dyno tune is good too!
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Old 10-03-2011, 10:43 AM   #23
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Valve cover and oil pan ordered got both for 108 total!
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Old 10-03-2011, 10:14 PM   #24
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Cool sounds like a good deal!
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Old 10-09-2011, 10:27 PM   #25
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Alright big steps today. Got the motor out, working from 11 am to 8 pm. Pics to follow. I got the valve cover, oil pan here in the mail for the 5.4. I got a sick deal on a HPS intake manifold, accufab throttle body, and accufab plenum, AND ARP head bolts!, for a thousand bucks! Those are in the mail and should be here monday. Dude should be here with the grinder for the manifold Mon or tues night. pulling the heads this week, then starting the rebuild!
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Old 10-09-2011, 11:14 PM   #26
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Looks good!
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Old 10-17-2011, 11:59 AM   #27
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Just rounded the "teardown" corner this weekend. Scrapping the block and heads for clutch money. Buildup starts this week. Only things I need, shopping for a clutch, and waiting for my cobra flywheel to come in the mail. And a passenger side motor mount.
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Old 10-17-2011, 06:24 PM   #28
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Started on oil pan on 5.4 today, all was very dirty, but mechanically sound. Took off the valve covers and this is what I found (pic)... I'm scared this is a project ender. I'll get the heads off tomorrow and I imagine if I see the valves hit pistons I'm screwed. What do you guys think? The gear broke clean apart. There is no visable damage besides the gear so far. Can this be a salvageable situation?
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Old 10-17-2011, 06:25 PM   #29
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Forgot the pic, here it is... This is the new motor.
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Old 10-17-2011, 11:53 PM   #30
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Keep posting up how your swap is going for ya!.. I always thought about doing this same swap myself!..
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Old 10-18-2011, 07:05 AM   #31
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I would breakdown the whole 5.4 motor and have it cleaned by a shop. It looks rough, I saw the pic before what you wrote and I got worried! Just be patient with this project and don't rush it. Ive seen a lot of people rush swaps and motor builds because they are excited and then it all goes wrong and if they just took some extra steps it would go right.
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Old 10-18-2011, 11:11 AM   #32
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That is good advice, but add one thing to it. What can I do to clean it off? I am 1900 dollars into this. I need a camshafts, clutch, battery and a motor mount. I have 400 left. I'm pretty much in DIY mode.
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Old 10-18-2011, 06:12 PM   #33
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Break down the 5.4 and get a lot of break cleaner and I mean a lot of it. Wipe down all of it first and get the most of it all off, then have fun spraying with the brake cleaner. I just use the Autozone stuff. But it might be good also to have a shop degrease everything. Then when it's done, assemble it all back and grease all the right parts. It might be a good time to replace the oil pump ( I'm pretty sure it stopped up with that mess ).
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Old 10-18-2011, 08:24 PM   #34
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That wont come clean like that. Id needs to be dipped in solvent for a day or so. You will have to chisel alot off before the dip. Ove had several motors come in like that an brake clean barely touches it. It needs to be submerged completely for hours at least. Its a big nasty mess
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Old 10-18-2011, 08:49 PM   #35
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The plan is a 5 gal bucket and 3 gallons of kerosene. That will get the heads, and the timing chains. I have to figure out how to soak the block. All the same it is not really that bad. There is no built up hunk, just a film on everything. What do you think to clean the inside of the blocks lower stuff. Can I use 800 grit sand paper on the piston tops and cylinder walls?
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