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.
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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.
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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.