Thinking of supercharging the 5.4 2v

[kep5niner]

After installing a new re-man’d 5.4 2v in my ‘03 EB, I’ve put about 5k miles on her working out any more write-ups. I went with JBA headers, eventually replaced both cats, and while I was there just threw on a Magnaflow muffler and rolled stainless tip. I’ve kind of fallen in love all over again. This truck sounds just like my dad’s ‘99 Lightning, which he’s owned since new. Of course when I get on it, it doesn’t have the legendary twin-screw whine of the Eaton supercharger like the Lightning, but all else sounds the same!

So that got me to thinking, why not supercharge the ol’ girl? I wouldn’t do a Lightning mod / swap for the Eaton. I’ve seen write-ups on the web, and it looks significantly more involved. I’ve seen Procharger kits of yester-year, but not sure if anything’s still available today for a bolt-on kit.

Anyone have any ideas or suggestions that wouldn’t involve massive supporting mods such as internals? I Magnacharged a 5.4 3v years ago, that’s still running strong over a decade later - sold it to one of my brothers years ago. Just thinking of more fun with this ‘03 Expy.

 

[kep5niner]

Got word back from Procharger, and no dice. I could Frankenstein a kit from them, but I’m looking for something a little more turn-key (or at least application specific).

 

[whtbronco]

You're clearly more experienced in this area than I am, but I was intrigued and did a quick search for superchargers. There's several ProCharger P1SC models on eBAY, which I suspect you've seen.

Anyway, this is the one that caught my eye. It's from Allen Engine Development and replaces the plastic intake manifold and uses a roots style blower. It's used, but I liked the all metal design. At $2200 I'd have to do a lot more research before I pulled the trigger.

1997-2002 F150 & Expedition 5.4L Allen Intercooled Supercharger Assembly | eBay

It is in flawless working order. No other parts are included.

www.ebay.com

 

[whtbronco]

I found the reason not go with the Allen supercharger, it uses an M90 which is the same unit used on the GM 3800 V6. It works good on the 3800, not enough for the 5.4 V8 though. Oh well, I liked the metal intake.

 

[kep5niner]

Good catch - I did take a quick look at it. Seems like a nice blower, but if Allen is not around anymore, could be challenging to find the rest of the components. It was a scavenger hunt enough to find all the pieces and parts (Motorcraft hoses, vacuum lines, etc) when I swapped out the long block!

The M90 blower was a good catch too. I’ve been searching the interwebs high and low, and just haven’t found a turn key kit like I’ve hoped.

Still just the research phase now….still haven’t broached the topic with my wife

 

[whtbronco]

LOL, I understand the potential "wife" limitation. Good luck with that.

It'll be interesting to see how this goes if you decide to pursue it.

 

[texasscot]

After installing a new re-man’d 5.4 2v in my ‘03 EB, I’ve put about 5k miles on her working out any more write-ups. I went with JBA headers, eventually replaced both cats, and while I was there just threw on a Magnaflow muffler and rolled stainless tip. I’ve kind of fallen in love all over again. This truck sounds just like my dad’s ‘99 Lightning, which he’s owned since new. Of course when I get on it, it doesn’t have the legendary twin-screw whine of the Eaton supercharger like the Lightning, but all else sounds the same!

So that got me to thinking, why not supercharge the ol’ girl? I wouldn’t do a Lightning mod / swap for the Eaton. I’ve seen write-ups on the web, and it looks significantly more involved. I’ve seen Procharger kits of yester-year, but not sure if anything’s still available today for a bolt-on kit.

Anyone have any ideas or suggestions that wouldn’t involve massive supporting mods such as internals? I Magnacharged a 5.4 3v years ago, that’s still running strong over a decade later - sold it to one of my brothers years ago. Just thinking of more fun with this ‘03 Expy.

I may be interested in replacing my 266k 5.4 2v at some point. Do you have a recommendation as to the source? There seems to be a number of choices.

 

[kep5niner]

AER was the remanufacturer I went with - they’re the same company that supplies long-blocks for all Ford dealerships. They were very easy to work with and even waived the core charge if I got it back to them within 30 days. The long-block 5.4 2v came with heads, timing chains and cover installed. I’ve timed a 3v before, so that was fun I’m glad I missed. AER claims to address all of the known deficiencies in the 2v (timing chain guides, tensioners, oil pump, etc.). Cost on my doorstep was about $3,100. I’ve put over 5,000 miles on the engine so far. Problem free.

 

[texasscot]

AER was the remanufacturer I went with - they’re the same company that supplies long-blocks for all Ford dealerships. They were very easy to work with and even waived the core charge if I got it back to them within 30 days. The long-block 5.4 2v came with heads, timing chains and cover installed. I’ve timed a 3v before, so that was fun I’m glad I missed. AER claims to address all of the known deficiencies in the 2v (timing chain guides, tensioners, oil pump, etc.). Cost on my doorstep was about $3,100. I’ve put over 5,000 miles on the engine so far. Problem free.

This is excellent information, many thanks. And, of course, Merry Christmas. That’s a good deal for sure. I’m tempted to preemptively do the engine swap to avoid the expensive temptation to buy a Land Cruiser on BAT should it suddenly peg out. Thanks again.

 

[kep5niner]

Found a blower kit here. Now just need to convince myself it’s worth $8k.

 

[whtbronco]

~425hp would be kinda fun in the Expedition, but that price tag is certainly steep.

 

[texasscot]

Is there any available info of the capability of the rest of the power train to handle this upgrade?

 

[kep5niner]

Great question. There is copious amounts of research I’d have to do before executing a plan like this blower.

Currently, I’m chasing a slight drivetrain vibration that has developed over 70 MPH, so yeah, I’d have to ensure everything else is locked in tight before throwing more power (read: money) at this EB.

 

[Hamfisted]

Maybe call the engine builder and ask what they used on the internals. It'll save you tremendous headaches down the road .... not to mention the wasted money ...

Hypereutectic Pistons Info






.

 

[kep5niner]

Just talked to the engine manufacturer. Definitely not forged pistons, but “hyper-silica” cast pistons. They said they’re better than the stock cast. A blower would void their 3 year / 100k mile warranty.

I did supercharge my stock ‘05 5.4 3v about 13 years ago, and she’s still running strong with out issue.

Plenty to think about.

 

[whtbronco]

I thought you could run some boost, less than 10lbs, with hypereutectic pistons and anything over 12lbs required forged without question. I suppose there are no guarantees without forged pistons and rods though.

You do have some serious thinking to do.

 

[GlennSullivan]

I thought you could run some boost, less than 10lbs, with hypereutectic pistons and anything over 12lbs required forged without question. I suppose there are no guarantees without forged pistons and rods though.

You do have some serious thinking to do.

I would say that safe would be more like 5-7lbs of boost and also keep in mind that the tune is also a key factor. Running low boost, with a safe A/F ratio and low timing advance will allow hypereutectic pistons to live in a boosted environment. I ran a supercharged 4.6 4V Mustang Cobra for 15 years with no issues because I didn't get greedy looking for more power.

 

[Hamfisted]

I would say that safe would be more like 5-7lbs of boost and also keep in mind that the tune is also a key factor. Running low boost, with a safe A/F ratio and low timing advance will allow hypereutectic pistons to live in a boosted environment. I ran a supercharged 4.6 4V Mustang Cobra for 15 years with no issues because I didn't get greedy looking for more power.

Yeah later Cobra motors had some forged internals ( crank ... but still hyper cast pistons....). They handle boost pretty well.






.

 

[GlennSullivan]

Yeah the Cobra 4.6 motors had forged internals. They were definitely built for boosting.

Sorry, I did not mention the year. The later 03 / 04 Cobra engines were built really strong. but the 96-98 Cobras (we had a 98) had a really good forged steel crank, but super weak powdered metal rods and Hyperucraptic pistons. Everyone - and I mean everyone - in my circle that pushed the boost and / or the tune on those engines either knocked the rods out of them or cracked pistons. Low boost and a safe tune are the keys to making these stock short blocks survive.

 

[kep5niner]

I would say that safe would be more like 5-7lbs of boost and also keep in mind that the tune is also a key factor. Running low boost, with a safe A/F ratio and low timing advance will allow hypereutectic pistons to live in a boosted environment. I ran a supercharged 4.6 4V Mustang Cobra for 15 years with no issues because I didn't get greedy looking for more power.

This kit advertises 8-9# of boost. And it looks like a learned a new term: hypereutectic. Is that what I mistakenly understood as “hyper-silica” pistons? Like I said, plenty of research to do.

I have custom tuned several vehicles over the years, and recognize the value, safety, and longevity of a good tune. For my ‘05 F150 3v, I drove it half way across the country to have the (late) Mike Troyer custom tune it after the blower install, after a local speed shop made a soup sandwich out of the tune.