03 4.6 swap?

[chopsieze]

Picked up an 03 with a 4.6 that I couldn't find the miss (as I have been reading tonight I wished I would have tried an intake gasket) but the motor started ticking/clicking.... not sure what it is. It's on the drivers side and seems to be under the valve cover so guessing valve or lifter. I'm not super experienced but always do my own work on my cars and motorcycles and want to attempt this.

I got a 97 Town Car motor that I heard run that sounds and even looks great. I read and read and after my head almost exploding finally just went for it in hopes for a half way easy swap. My neighbor wanted the tranny from the Town Car so we split the $500 so I got a great sounding motor for $250.

Just getting ready to pull the motor (never done one) and wondering if anyone can point me to any decent guides/how to's, I can't find any yet. I have a haynes (maybe chiltons) and should probably get a service manual as I don't think my manual is very detailed with torque specs etc and covers a lot or years/models.

Thanks!

 

[Bedrck47]

Get the FORD Workshop Manual on DVD The DVD these are factory manuals

 

[Gapafudus]

I agree with Bedrck, that's the only way u can find how to do it, or let someone that has done it before walk you through. You ain't going to find no article online or any YouTube video how to do it. It is to much to recorded and explain, or even write about it. If you get yourself a workshop manual, you will be able to do it, it's a little be confusing the way they describe the work procedures, but it can be done.

 

[stamp11127]

There are two flavors of that engine, you may want to check the crown Vic motor and make sure it is the same.

More info:
https://en.m.wikipedia.org/wiki/Ford_Modular_engine

 

[cajun01]

It needs to be a PI engine and you have to buy new motor mounts and modify them. Also you would need a new front cover. Our blocks are Aluminum and the crown Vic is iron. It took me months to do the swap, because of issues and research

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[chopsieze]

Hoping a friend has a service manual, otherwise will be buying one.

Cajun, thanks, I have no idea what I'm going to run into. I was doing some research then gave up as there is so much info out there. The replacement motor is iron and current is aluminum. I also think the replacent has non PI heads and current PI. I was told my intake would fit the non PI but now thinkng that's not the case. I have read about adapters sold/made by someone. Also read using PI heads on a non PI block gives you a decent HP gain because of compression increase and if I want a real boost to do cams and springs. I just don't know if my heads are in great shape and also don't want to have to worry about always being able to find 91+ octane.... Not to mention if I go that far I might as well consider rings and everything else on the motor. Trying to get this done on the cheap!

Hoping this doesn't turn into a nightmare.

 

[cajun01]

You will need to have the computer tuned by someone if you are using non PI heads. That's a pile of money.

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[chopsieze]

Cajun, can you or anyone else break down what exactly I would need to do the swap with the replacement motor I have (97 Town Car). If I keep the heads on it can I use the truck intake with new PI gaskets of course? I have all the accessories and motor mounts from the town car. It makes sense I would need to tune it afterwards.

I did just see a motor posted this morning local to me from an 04 F150 with 91,000 for $400 that I'm about to call about.... Claims its in great shape but I don't think it'so in the truck anymore so I won't be able to hear it run... I assume that would be almost the same engine as my 03 Expedition.

 

[cajun01]

The 04 F150 engine is a PI head and 2v, so it will be a better option.
-The Engine mount plates had to be modified.
-The front timing cover for the Aluminum block doesn't line up with the Iron block. I used an 05 F150 STX front timing chain cover. It has the high mount power steering mounts like the Expedition.
-Everything needs to be swapped over except the block and heads.
-Expedition has 2 knock sensors in the valley, Fe block has one. I mounted the other behind the passenger head.

It was a hell of a job. It took me a couple months in my spare time. Everything I researched was wrong about the Iron to Aluminum swap.

 

[cajun01]

Here are both valleys showing the different knock sensors

 

[chopsieze]

The 04 F150 engine is a PI head and 2v, so it will be a better option.
-The Engine mount plates had to be modified.
-The front timing cover for the Aluminum block doesn't line up with the Iron block. I used an 05 F150 STX front timing chain cover. It has the high mount power steering mounts like the Expedition.
-Everything needs to be swapped over except the block and heads.
-Expedition has 2 knock sensors in the valley, Fe block has one. I mounted the other behind the passenger head.
View attachment 17582 View attachment 17583
It was a hell of a job. It took me a couple months in my spare time. Everything I researched was wrong about the Iron to Aluminum swap.

View attachment 17584

Wow, thanks for that info. That's a bummer and maybe more than I want (or even have time) to take on right now. Do you have a swap thread I can look over by chance? I'd really like to know what all would be involved. I didn't really want to mess with the timing chains, although I've read the plastic guides wear and wouldn't hurt to change them. I suppose you need new gaskets for the covers, probably lots of new gaskets which I expect but thithat would all add up... how much do you estimate you had in extra parts you had to purchase? Wondering if I should just rebuild and go through the motor I have.

Not sure what to do here, I don't really have free time to begin with and since I don't have a garage I have to work on the truck about 20 minutes from home.

 

[chopsieze]

I'm going to have to run out to my truck and confirm if it is aluminum or iron (I thought it was aluminum). The guy thought his was iron but wasn't at his shop at the and couldn't remember since he pulled it out 3 months ago. He already has another buyer but is willing to hold it for me till this later afternoon.

 

[stamp11127]

I don't have a garage either but I do have a bunch of pines trees - so does that make me a pine tree mechanic? The only thing I miss is the flat floor and protection from the weather. When it isn't hot like it has been lately, it actually is pretty nice being outside working on the projects.

 

[chopsieze]

I don't have a garage either but I do have a bunch of pines trees - so does that make me a pine tree mechanic? The only thing I miss is the flat floor and protection from the weather. When it isn't hot like it has been lately, it actually is pretty nice being outside working on the projects.

You might not have a flat floor but at least you have a bed of pine needles to lay on

I don't have any off street parking so I can't do big projects like this at home or will risk getting towed... it's a pain to lug tools back and forth anyway and the street is black asphalt. We just got done with a couple weeks of hot with some days up to 120 degree heat index. I've been taking the mornings off and doing my outside stuff till I'm dried up like a raisin then go into work.

 

[cajun01]

Expedition 4.6L's are Aluminum for the second gen. 2003+. I didn't do a build thread. Maybe one day

 

[chopsieze]

The F150 motor was the exact same as mine, aluminum block and everything looked the same but the guy had left it sitting outside for who knows how long. He claimed he drove it home, ran great and only had it out of the truck for 4 months and it was in his shop (but no way). There was water in the spark plug wells and everything was corroded like crazy, pullies were rusty and on top of it, it was seized. Have to keep looking. I know of a Mustang motor that is aluminum... I think between 97-99 model. Maybe it would be a good candidate if he will sell it.

 

[eetchickn]

I've been working on a swap in my 03 over the last year. Bought it with a locked engine, looks like the oil was never changed.

I put in a used long block from a 1998 with PI heads. Swapped over the intake and all the other accessories. Had to modify the engine mounts, and find a place for the second knock sensor as well. All in all it wasn't that bad.

Its running but I am chasing lean bank 2 at idle and lean bank 1 at 2500rpm and above, and it has no power at all. Very rough idle after its warm, maybe a hard miss. Next steps are unhooking the headers to check for a clogged cat, and some makeshift smoke test for vacuum leaks.

 

[chopsieze]

I've been working on a swap in my 03 over the last year. Bought it with a locked engine, looks like the oil was never changed.

I put in a used long block from a 1998 with PI heads. Swapped over the intake and all the other accessories. Had to modify the engine mounts, and find a place for the second knock sensor as well. All in all it wasn't that bad.

Its running but I am chasing lean bank 2 at idle and lean bank 1 at 2500rpm and above, and it has no power at all. Very rough idle after its warm, maybe a hard miss. Next steps are unhooking the headers to check for a clogged cat, and some makeshift smoke test for vacuum leaks.

That's cool you got it going at least. I'm interested to hear when you figure out the miss.

I didn't realize there were any 98s with PI heads. I found a wrecked 01 f150, supposedly taken care of with 139,000 miles I want to get my hands on. It is an iron block but hoping I can move everything over easy enough. I think I remember reading the iron blocks only have one knock sensor so I will have to do what you did. Not sure if I will have change the front cover or not.

 

[eetchickn]

I didnt have to change the front cover as the used engine came out of another Expedition. One thing I do recall having a hell of a time with is matching up the radiator connection to the block. The block discharge from the doner engine was set up for an oil cooler or a remote filter. The challenge is finding one where the outlet comes out at the right angle to miss the PS pump and also accommodate the overflow inlet. I've got some custom household plumbing going on now.