Aviator 4v swap - Mustang Evolution

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Old 09-27-2014, 01:23 PM   #1
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Aviator 4v swap

So, I've been kicking around the idea of the coyote swap, or a 4V for my 2000 GT. This thread isn't about what should or shouldn't I do, because as luck would have it I bought an entire 04' aviator for cheap from a buddy of mine. I've heard it done before, but never really found a specific write up or answeres to my questions. So I did a ton of research, and I've got a pretty good idea what I need to do. But as we know, something like this may have alot of little things to adapt. Unfortunately I will be out of town for the next month for work, but sometime in November I plan on doing the swap (assuming I don't run into any big issues). I'll keep updates for those that might be interested in the project!
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Old 09-27-2014, 03:08 PM   #2
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Is it a 4.6 4V or a 5.4 4V? I'm looking forward to updates
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Old 09-27-2014, 03:30 PM   #3
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Quote:
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Is it a 4.6 4V or a 5.4 4V? I'm looking forward to updates
It has to be the 4.6 4v, as it was the only engine available. Aviator's did not have an option for a 5.4 4v.
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Old 09-27-2014, 04:38 PM   #4
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Yeah its a 4.6 4v. It's the exact same long block as what is in the 03-04 mach 1's.
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Old 09-27-2014, 04:41 PM   #5
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I'm gonna try to keep the aviator intake too, since I've got a hood to clear it, and I can rig the imrc valves to open.
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Old 09-27-2014, 05:57 PM   #6
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Quote:
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It has to be the 4.6 4v, as it was the only engine available. Aviator's did not have an option for a 5.4 4v.






Quote:
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Yeah its a 4.6 4v. It's the exact same long block as what is in the 03-04 mach 1's.
Ah ok , it was the Navigator that got the 5.4 then correct?
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Old 09-27-2014, 07:38 PM   #7
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Ah ok , it was the Navigator that got the 5.4 then correct?
You got it, the Aviator was the sister of the Navigator
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Old 09-27-2014, 08:33 PM   #8
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And to be clear, the aviator has a 6 bolt cast crank. So it's the same as the 03-04 mach 1 with an auto tranny. I'm going to go with some Longtubes and obviously a tune afterwards. So assuming I can get the intake imrc's to work, I'm hoping to be around 300 rwhp.
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Old 09-28-2014, 03:21 PM   #9
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Cool!
I look forward to following along.
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Old 09-28-2014, 03:33 PM   #10
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I bought some small odds and ends I know I'm gonna need yesterday and today. Also figured I'd do my rear brakes as the pads are getting low.
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Old 09-28-2014, 07:52 PM   #11
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Good deal. Cast crank is fine if you keep it under 7k. I'd just delete the IMRCs, completely not needed on a Mustang. Keep us updated.
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Old 09-28-2014, 08:35 PM   #12
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Do you know what cams those aviator 4.6's have? Depending on the cam profile you may want to swap in some 96-98 cobra cams before you drop her in. Pick up a fee more ponies and gain some low end grunt.
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Old 09-28-2014, 11:15 PM   #13
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Thanks guys! The Aviator intake is similar in theory to the fr500 intake. So the imrc's are controlled by a stepper motor. I'm gonna try to hook em up, but if not I was going to wire them to stay open. I forget where I saw it, but there was a shop that did a few of these swaps and they all kept the imrc open too. And the cams are the same as the 99-01 cobra, and 03-04 mach 1. I thought about grabbing some 96-98 cobra cams, but I don't really want to deal with setting the timing up. My plan was to not have to Crack it open at all.
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Old 11-14-2014, 09:34 PM   #14
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Well, got the 4v out of the aviator today. It was a total PITA since you're really suppose to lift the body off the frame, but nobody got time for that. A Sawzall and torch did a decent job of getting the front end off.....
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Old 11-14-2014, 09:35 PM   #15
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I also got my headers in finally, and on Monday I'm going to work on getting the 4v ready to drop into my New Edge (still gotta pull the 2v outta her).
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Old 11-20-2014, 08:13 PM   #16
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Another update: swapped a mustang oil pan and mach 1 oil pick up tube onto the 4v. The 4v pick up tube is just and tad bit bigger than the 2v (see pics ). And the 2v tube will bolt up, but it's lose. Installed new motor mounts and deleted the egr (yes I'm getting it tuned). Also I'm using the aviator thermostat housing.
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Old 11-20-2014, 08:25 PM   #17
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I also used my GT throttle body (I have a bbk 75mm). All you have to do is turn it upside down and it'll work fine. I was finally able to use the lift today and was able to pull the old tired 2v out. Man was it dirty! I pulled the tranny out with it and I'm swapping in a tubular k member with the 4v and longtubes. I will be using my stock a arms, with spring perches.
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Old 11-20-2014, 11:34 PM   #18
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Looking good so far. Can't wait to hear about the results. How many miles did the 2v have?


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Old 11-22-2014, 10:29 PM   #19
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That 2v had over 250k on the short block. The rings were shot, and blowing smoke as you can see from how dirty it was. Lol today I installed brand new poly bushings in the a arms, and hacked up the 2v harness a bit. I have the factory Aviator harness, so I took the connectors for the COPs off that and I'll be splicing them into my harness. The good news is, the wire colors are the same from my harness to the 4v, so it's going to be pretty easy. Match the colors, and since I'm using the 4v connectors, I don't have to worry about reversing the polarity. Plus it'll look stock. I'll also have to splice In the 4v alternator connector, but again since it's from the 4v harness, it's a simple splice. I ordered a King Cobra clutch, and resurfaced my flywheel. I also got a new hydrobooster since mine was leaky, and nows a good time to imstall it. I have to go back to work on monday, so the next time I'll be working on her will be next saturday. Just have the wiring and suspension left to put together. And then it'll be almost complete.
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Old 11-29-2014, 05:44 PM   #20
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Worked on the suspension alittle today. Put new poly bushings in the a arms, and bolted them up to my UPR k member. Let me take a moment to say that the stock a arms will bolt up, however, I ended up grinding down the front of the most forward facing bushing. This allowed them to slide in with a little persuasion...lol also installed new inner and outer tie rods for the steering rack.
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Old 11-29-2014, 05:47 PM   #21
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Also, my car is sitting below the immortal Hulk Hogans Charger
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Old 11-30-2014, 12:28 PM   #22
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Hulk hogans? Lol

Good stuff man. Pretty sure I'll going 4v later on.
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Old 11-30-2014, 12:37 PM   #23
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Lol yeah. I'm in Tampa, and the shop I'm at has been working in his cars for years. It needs new carbs.
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Old 11-30-2014, 12:57 PM   #24
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That's awesome lol
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Old 12-14-2014, 08:25 PM   #25
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Just a quick update, installed a new hydrobooster as mine was alittle leaky. But next week, I'm gonna start putting the 4v in the car.
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Old 12-20-2014, 08:29 PM   #26
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My buddy decided to do the wiring this past week, so unfortunately I wasn't able to get any pictures during the process, but I have the finished product:
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Old 12-20-2014, 08:30 PM   #27
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He wired them into the 4v harness, and the cables are all the same colors between 2v and 4v, so it's really not that hard. Next up is the clutch install and tranny. Headers, then she'll be good to go back in the car!
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Old 12-20-2014, 08:39 PM   #28
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You make it look so easy!
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Old 12-20-2014, 08:41 PM   #29
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Looking great!

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---------- Post added at 09:41 PM ---------- Previous post was at 09:41 PM ----------

Good Xmas present to you! A fresh 4v

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Old 12-20-2014, 08:46 PM   #30
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Quote:
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You make it look so easy!
Haha if only it was. Dont get me wrong, it's not a hard swap. Some do it in a weekend. But I added alot of new and aftermarket parts. And trying to do it while working my full time job. It's been dragging on alittle longer than I had hoped for, but at least I know it's being done right the first time.
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Old 12-20-2014, 08:47 PM   #31
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Looking great!

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---------- Post added at 09:41 PM ---------- Previous post was at 09:41 PM ----------

Good Xmas present to you! A fresh 4v

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Lol it probably won't be done by Christmas, but I'm going out of town for work in mid January so I hope to have it running by then.
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Old 12-20-2014, 10:50 PM   #32
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Either way you have made some good progress. Sometimes I wish my engine would go so I could do a swap, lol. I guess I could but I don't have enough motivation.

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Old 12-21-2014, 02:09 AM   #33
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Yea... I was just saying that to myself as I was reading this post. I never did do my t56 swap unless my tranny went out. I wanna do a coyote or a 4v swap whenever my engine goes.


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Old 12-21-2014, 07:37 AM   #34
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Any lincoln Mercury Ford engine will fit , since they are the same motors
Only thing you will have to do is keep the aviator wiring harness
and that should safice , wiring harness is basicallythe main thing in any engine swap
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Old 12-21-2014, 08:33 AM   #35
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Just keep a lookout in your local craigslist and junkyards. Then if you find a 4v (out of any of fords brands like ultrawhite mentioned), grab it up. The best time to do this swap would be while your current engine is good, that way you won't be rushed for time, or if you have another DD. Luckily for me both those apply, so I can afford to do it right. Otherwise, you'll cut corners, and/or get inferior parts, and that will most definitely come back to haunt you later.
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