2002 Navigator 5.4L Intech swap into a 2002 5.4L Expedition

[86caprirs]

I got a 2002 Expedition with a 5.4L and a 4r100 trans. The engine has 400,000 km on it and it is leaking oil from the head gasket like crazy. I have found a 2002 Lincoln Navigator in the wreakers with the 2002 intech 5.4L 4V engine.

Has anyone actually done this swap and been successful? I want to know what it would take to do the swap. I am guessing engine, exhaust y pipe, engine harness, pcm and maybe cluster? The 5.4L should bolt to the trans no problem. I am not sure about the torque converter. I have access to a IDS to reprogram keys to the pcm. I want to know if the wiring is the same from both vehicles? How much of a pain this will be?

From most posts I have found everyone is guessing if it will work. I want to know if someone has done this swap and can help me out.

Thanks
Shane

 

[stamp11127]

There is one thread on here where a member in California (I think) did the same swap. It is possible, all I will say is it will be a very tight engine compartment. I think the blocks are the same, just everything else is different. If it was me, I wouldn't do the swap.

 

[86caprirs]

Well I am not asking about opinions on if I should do the swap or not. I am doing the swap and want to know what I need for the swap from people that have done it. It will be no tighter then a Navigator engine bay and it is already tight with the 5.4L in it already.

The only swap thread I have seen is someone doing a supercharged 5.4 swap from a 4.6L swap

 

[86caprirs]

Anyone?

 

[Bedrck47]

Guess your not interested in opinions and you can't find anyone that has done it before I would say your on your own But when you do finish the project it would be nice if you posted the procedure as it may help the next member

 

[MISTERgadget]

It is an easy swap. The engine compartment in a 2002 navigator is the same as a 2002 Expedition. 86caprirs, it sounds like you have a good handle on what you're dealing with and the differences/similarities with Mod Motors.

I did a DOHC swap in my 2003 Lightning so I went through all of this myself too.

How I would go about it depends a bit on what parts you have access to and the relative costs.

Base scenario - take the engine, complete with intake manifold, airbox, throttle and cruise control cables. Your PCM will run the 4v engine no problem, 4r100 bolts right up. You can use your existing engine wiring harness or the 4v's. Only difference in wiring is that the coil pack wires run separately from the injectors, so if reusing your harness, you need to separate them, and the polarity of the pins is the opposite on a 4v from a 2v - flip the pins. Just reprogram your PCM for the injector size and higher redline.

If the price for everything is about the same, I would take the wiring harness and PCM with it, then use your IDS tool to reprogram PATS.

The exhaust manifolds are different but the y-pipe should be the same,

 

[MISTERgadget]

Guess your not interested in opinions and you can't find anyone that has done it before I would say your on your own But when you do finish the project it would be nice if you posted the procedure as it may help the next member

He's interested in feedback, just not random conjecture from people who have no idea what they're talking about

 

[86caprirs]

I may have to do that. My 5.4L 2V is not doing well and why replace it with another 2V when I have 4V sitting at the yard.
My concern is there was issues and no one posed them. I did a search on Inford with the Navi VIN and the truck is identical to mine except for the 5.4L is a 4V. Same year and same options including trans and transfer case. In everything I have seen this should be an easy swap with the engine, harness, pcm and exhaust pipe. My question is the bulk head connector for the PCM in the engine bay wired the same between my Expedition and the donor Navigator?

 

[Bedrck47]

He has been talking about this swap for over 3 years look at his previous posts

 

[Bedrck47]

Would suggest that you get the wiring diagrams for both so you can compare the connectors for the PCM

 

[86caprirs]

He's interested in feedback, just not random conjecture from people who have no idea what they're talking about

The hard part is that everyone has an opinion. I need facts. I don't want to hear that it is hard and it is tight and "I" wouldn't waste my time. I am the kind of guy that gets it done. I just want to know the issues people had with this swap and if it worked.

Thanks MISTERgadget. I was going to use the PCM from the Navigator so that it runs like a stock Navigator. I don't want to pay for a tune if I don't have to. So I will grab the complete engine harness and PCM.

You said your 5.4L y pipe did match up? That is good. One less thing to buy.

Oh and MISTERg? if you get a change I would love to see pics of your Lightning with the 5.4 4V in it and a the M114 supercharger on it. I have a 2003 Cobra with the 4V 4.6L bumped up to 480HP at the rear wheels. I am a huge sucker for First gen Lightning. My wife would love one.

 

[MISTERgadget]

I may have to do that. My 5.4L 2V is not doing well and why replace it with another 2V when I have 4V sitting at the yard.
My concern is there was issues and no one posed them. I did a search on Inford with the Navi VIN and the truck is identical to mine except for the 5.4L is a 4V. Same year and same options including trans and transfer case. In everything I have seen this should be an easy swap with the engine, harness, pcm and exhaust pipe. My question is the bulk head connector for the PCM in the engine bay wired the same between my Expedition and the donor Navigator?

Almost all of the pins will be the same, they are consistent across mod motor applications on the EEC-V PCM. That's not the connection to worry about though, at the starter solenoid that harness splits into two connectors, one for the engine harness and another for the trans harness - the Navi engine harness should plug right into that one, just confirm the pinouts on both from a service manual. A couple pins may need swapped but it will be mostly identical.

 

[86caprirs]

He has been talking about this swap for over 3 years look at his previous posts

Before it was a dream, now it is a reality and three years ago nobody responded to my post. I have looked at a new F-150 to buy and it is $800 a month payments. For that I can keep my Exped and put some money into her. She owes me nothing at this point.

 

[86caprirs]

Almost all of the pins will be the same, they are consistent across mod motor applications on the EEC-V PCM. That's not the connection to worry about though, at the starter solenoid that harness splits into two connectors, one for the engine harness and another for the trans harness - the Navi engine harness should plug right into that one, just confirm the pinouts on both from a service manual. A couple pins may need swapped but it will be mostly identical.

Excellent. I really appreciate your help. This makes me feel a lot better doing the swap now.

 

[MISTERgadget]

Here's the full build thread on mine:

https://www.theturboforums.com/thre...uild-update-e85-1000hp-and-vid-jul-12.307516/

I can't confirm that the y-pipe matches up since we took all that out for a custom turbo setup but I don't see any reason it shouldn't.

 

[86caprirs]

No worries there. I can get both pcm wire diagrams off the Ford website. I have been looking at the for a day/night now and it looks like Ford was lazy enough not to create a different harness between the Navi and Exped with the exception of a couple wires to re-pin

 

[MISTERgadget]

No worries there. I can get both pcm wire diagrams off the Ford website. I have been looking at the for a day/night now and it looks like Ford was lazy enough not to create a different harness between the Navi and Exped with the exception of a couple wires to re-pin

I'm working on a Lightning swap into my 1998 expedition now, and for that truck there are only 8 pins different (out of 104) from the 1998 PCM to the 2003 harness I have. Very little considering everything that changed from 1998 to 2003, digital ODO, VSS vs OSS, etc.. etc..

 

[86caprirs]

MISTERg..... I bow to you. A 1000 hp 9 second turbo Lightning build! Congrats man

 

[Bedrck47]

He's interested in feedback, just not random conjecture from people who have no idea what they're talking about

I realized he was looking for some feed back And he wasn't getting any.

My response was to ask him to post the procedure once he finished the project so it could help others.

Your comment was unnecessary

 

[86caprirs]

I realized he was looking for some feed back And he wasn't getting any.

My response was to ask him to post the procedure once he finished the project so it could help others.

Your comment was unnecessary

Gentleman....Lets be adults here.

I will be posting pics when the time comes. Right now it is snowing and -20 degrees Celsius outside and I want to go get this engine. Yes I was looking for real info not opinions and unfortunately it is hard to read a post when you can't tell if it is a shot or support. Come on, we all have had someone misread a text (mostly women) and it turns south. LOL