As promised, here is the write-up on our Lightning supercharger (SC) install. This write-up is not intended to teach anyone anything. If you undertake this swap, you do so at your own risk. This write-up is strictly for informational purposes. This write-up is specific to a 2004 Expedition (I assume the 03 would be identical). If you have a 1st generation Expi, the install should require less fab work. This swap will only work for the 5.4L 2V motors.
If you find any errors, please feel free to make corrections. I take no pride in ownership here.
Gathering parts:
Lightning SC 101: Ford used 2 different SC assemblies on the Lightning: the 1999 & 2000 model years used a 9-row Intercooler (IC) and the 2001-2004 used a 10-row IC. According to most folks on the Lightning forums, the 9-row IC assembly tends to leak coolant over time and was a recall item by Ford. I didn’t know there was a difference when I bought either of my units and of course, I ended up with one of each. To hopefully alleviate any future leakage problems, I opted to purchase the 9-row Xtreme (aftermarket) IC from Lightning Force Performance (http://www.lightningforceperformance.com).
There are plenty of Lightning SCs available out there…eBay, Lightning Rodder forum (www.lightningrodder.com), and National Lightning Owners Club (www.nloc.net) always have some listed. Both forums have a for-sale section that should have 90% of what you will need to do this swap. What you can’t find there, at your local salvage yard, or your local Ford dealer, you can get through Mike Dunn at Mad Enterprises. Mike has an AWESOME list of all the parts that you will need to complete this swap (http://www.madenterprise.com/catalog/scparts.htm). He will basically sell you everything you need in kit form. Whatever you can’t find yourself, Mike can get for you. I used him for the Lightning intake manifold bolts, SC pulley bridge bolts, and the Lightning alternator brackets. He hooked me right up. He is incredibly knowledgeable about Lightnings and can answer any question you may have. NOTE: If you have the plastic Expi intake manifold as we did, you will have to purchase new intake bolts. You can reuse the thermostat housing bolts however.
UPDATED ITEM Both our SC units came with 42# injectors (stock size). Because these injectors were an older style, we had to purchase adapters to connect our Expi injector connectors. We hit Summit Racing and purchased their Ford Racing kit, part # M-14464-U2J. I believe the kit was $50. Anyways, just wanted to add that to the parts list.
One additional part I would like to mention here that is not required but certainly recommended by most is the oil separator. Depending on the brand you choose, this item will be important very early in the assembly process. An oil separator simply removes any oil from the PCV hose prior to entering the plenum. When the engine is under boost, the SC will actually suck oil through the PCV and draw it into the SC and then into intercooler (IC) itself. Over time, the oil clogs up the vents on the IC reducing its effectiveness…not to mention making a big mess inside the plenum, SC, and the IC. The two pics below show a clean IC vs. an oil-soaked IC.
Now onto the fun stuff!
Disassembly:
As you can see our Expi motor compartment looks like most any other. The only mods we did prior to SC installation were a Poweraid throttle body spacer, a K&N CAI, Flexalite electric fans, and a PA Performance 200 amp alternator.
We started by removing everything associated with the Expi plenum and intake manifold. You will notice that the heater hose connection on the manifold is different between the Lightning and the Expi.
Here is what you will see with everything off:
SC Install:
With everything apart, this is a GREAT time to swap spark plugs. During my research, I found that a lot of Lightning owners use the NGK TR-6 plugs gapped at .035. I have always been a Motorcraft guy but when in Rome, do as the Romans.
For intake gaskets, we went with Felpro for the 2003 Lightning. The only difference between the Lightning intake gaskets and Expi intake gaskets is an extra alignment pin on the top side (fits into a hole on the Lightning intake). I highly recommend replacing all the gaskets during the install. If you get a SC with the 9-row IC assembly, any of your local parts stores can get the gaskets for you for about $80 or so. The 10-row assembly is quite a bit pricier ($170). For our 10-row assembly, I called Sam at Bob Utter Ford (http://www.trademotion.com/partlocat...?siteid=213787) and he really hooked us up. He sold me the 10-row gaskets for $103. Quite a big difference in price. Bob Utter Ford sells at wholesale prices; I highly recommend giving them a call…ask for Sam.
NOTE: Depending on your choice of oil separator, this will be a critical step. The factory Lightning PCV hoses form a giant “T”. The long edge of the T connects to a nipple on the lower rear of the Lightning intake manifold. This nipple is inaccessible once the intake is installed. One end of the short side connects to the PCV valve and the other to the plenum directly behind the IAC. We choose an oil separator manufactured by L&S Automotive (L&S website: http://www.lnsauto.com/articles/ford..._article.shtml). Per the L&S instructions, the long side of the T is disconnected from the other two sides and a plastic cap is used to block it (the long side) off. We simply discarded the entire T and affixed the plastic cap directly to the nipple. This step simply gave us less clutter around the intake and fuel rail.
If you find any errors, please feel free to make corrections. I take no pride in ownership here.
Gathering parts:
Lightning SC 101: Ford used 2 different SC assemblies on the Lightning: the 1999 & 2000 model years used a 9-row Intercooler (IC) and the 2001-2004 used a 10-row IC. According to most folks on the Lightning forums, the 9-row IC assembly tends to leak coolant over time and was a recall item by Ford. I didn’t know there was a difference when I bought either of my units and of course, I ended up with one of each. To hopefully alleviate any future leakage problems, I opted to purchase the 9-row Xtreme (aftermarket) IC from Lightning Force Performance (http://www.lightningforceperformance.com).
There are plenty of Lightning SCs available out there…eBay, Lightning Rodder forum (www.lightningrodder.com), and National Lightning Owners Club (www.nloc.net) always have some listed. Both forums have a for-sale section that should have 90% of what you will need to do this swap. What you can’t find there, at your local salvage yard, or your local Ford dealer, you can get through Mike Dunn at Mad Enterprises. Mike has an AWESOME list of all the parts that you will need to complete this swap (http://www.madenterprise.com/catalog/scparts.htm). He will basically sell you everything you need in kit form. Whatever you can’t find yourself, Mike can get for you. I used him for the Lightning intake manifold bolts, SC pulley bridge bolts, and the Lightning alternator brackets. He hooked me right up. He is incredibly knowledgeable about Lightnings and can answer any question you may have. NOTE: If you have the plastic Expi intake manifold as we did, you will have to purchase new intake bolts. You can reuse the thermostat housing bolts however.
UPDATED ITEM Both our SC units came with 42# injectors (stock size). Because these injectors were an older style, we had to purchase adapters to connect our Expi injector connectors. We hit Summit Racing and purchased their Ford Racing kit, part # M-14464-U2J. I believe the kit was $50. Anyways, just wanted to add that to the parts list.
One additional part I would like to mention here that is not required but certainly recommended by most is the oil separator. Depending on the brand you choose, this item will be important very early in the assembly process. An oil separator simply removes any oil from the PCV hose prior to entering the plenum. When the engine is under boost, the SC will actually suck oil through the PCV and draw it into the SC and then into intercooler (IC) itself. Over time, the oil clogs up the vents on the IC reducing its effectiveness…not to mention making a big mess inside the plenum, SC, and the IC. The two pics below show a clean IC vs. an oil-soaked IC.
Now onto the fun stuff!
Disassembly:
As you can see our Expi motor compartment looks like most any other. The only mods we did prior to SC installation were a Poweraid throttle body spacer, a K&N CAI, Flexalite electric fans, and a PA Performance 200 amp alternator.
We started by removing everything associated with the Expi plenum and intake manifold. You will notice that the heater hose connection on the manifold is different between the Lightning and the Expi.
Here is what you will see with everything off:
SC Install:
With everything apart, this is a GREAT time to swap spark plugs. During my research, I found that a lot of Lightning owners use the NGK TR-6 plugs gapped at .035. I have always been a Motorcraft guy but when in Rome, do as the Romans.
For intake gaskets, we went with Felpro for the 2003 Lightning. The only difference between the Lightning intake gaskets and Expi intake gaskets is an extra alignment pin on the top side (fits into a hole on the Lightning intake). I highly recommend replacing all the gaskets during the install. If you get a SC with the 9-row IC assembly, any of your local parts stores can get the gaskets for you for about $80 or so. The 10-row assembly is quite a bit pricier ($170). For our 10-row assembly, I called Sam at Bob Utter Ford (http://www.trademotion.com/partlocat...?siteid=213787) and he really hooked us up. He sold me the 10-row gaskets for $103. Quite a big difference in price. Bob Utter Ford sells at wholesale prices; I highly recommend giving them a call…ask for Sam.
NOTE: Depending on your choice of oil separator, this will be a critical step. The factory Lightning PCV hoses form a giant “T”. The long edge of the T connects to a nipple on the lower rear of the Lightning intake manifold. This nipple is inaccessible once the intake is installed. One end of the short side connects to the PCV valve and the other to the plenum directly behind the IAC. We choose an oil separator manufactured by L&S Automotive (L&S website: http://www.lnsauto.com/articles/ford..._article.shtml). Per the L&S instructions, the long side of the T is disconnected from the other two sides and a plastic cap is used to block it (the long side) off. We simply discarded the entire T and affixed the plastic cap directly to the nipple. This step simply gave us less clutter around the intake and fuel rail.