HI!... Would like a bit of advice on this upcoming project I plan on doing. Last year I picked up a mint (zero rust) 1999 Ford Ranger Sport. It currently has a 3.0L, auto (4R44-E), 7.5 rearend, 3.73 gears. It's a good truck. Picked up cheap. Had 153,000kms on it. Old man owned it and took very good care of it. I use this as a daily driver. Runs good but is massively under powered.

My plan is to swap in a 4.0L SOHC. I already have a 09 4.0L SOHC with only 23,000KMS on it. Basically new. I just finished parting out a 2001 Ford Explorer that came from the factory with a 4.0L SOHC and 5R55-E trans. I saved the Explorer instrument cluster, PCM, and engine wiring harness. Also the 8.8, 3.73 gear rearend.

Now I've done a ton of engine swaps before but never with this much electronics before.

If I install the 09 4.0L SOHC to the Explorer's 5R55-E and install it in the 1999 Ranger, using the Explorer's PCM and instrument cluster, will it be plug and play and fire up? If the PATS gives me a problem I have a local tuner that can shut the PATS off for me. I do understand that a custom tune might have to be used but was planning on having it tuned anyways. I know all the mechanical stuff will bolt right in. Some fabrication will be necessary but that is no problem for me. I used to work in a fabrication shop. It's just the electronics aspect I'm worried about.

Has anyone done a swap like this before? Any help on this would be greatly appreciated.

Thanks :

Neal.

 

Little bit of info here and some links.

https://www.ranger-forums.com/8-cyli...3/#post2111524

 

The 2001 PCM should be fine with the '09 4.0l SOHC and 5R55E trans

I would check sensor locations and connectors on the '09 and '01 engines, if you still have the '01, they may be at different location and use different connectors, so swapping lower and upper intakes make be more practical than extending wires or matching connectors.
'09 may also be "drive by wire" throttle setup which won't work with 2001 computer.

I think the '01 still had separate coolant temp sensors on the thermostat housing as well, the '09 will only have one, for the PCM, in '09 the PCM ran the dash temp gauge, '01 dash gauge had its own sender.

In any case the thermostat housing should be changed because they did leak after a few years, and also replace Knock sensor, under upper intake, it's wires would get brittle and break, and it is hard to get at.

If you have the matching PATS keys for the '01 PCM then you can remove the key cylinder from the '99(and door cylinders) take it to a locksmith to see if he can rekey it, either repin the cylinders or recut the keys.

Or yes, have PATS test removed from PCM

 

HI!... None of the Rangers came with DBW. All had mechanical TB's. Engine will be getting all new sensors. This 09 is going in a 99, with a 01 PCM. Any sensors will be spliced to make fit. Have both 09 and 01 engine harnesses.

 

Explorers started coming with drive by wire in mid-2000's, you didn't mention what the '09 4.0l SOHC was out of, I assumed explorer since it was included with 2001 explorer 4.0l and computer.

I wouldn't bother with new sensors, 90% of sensors that are replaced by DIYers were working just fine.
50% of sensors replaced by professional mechanics were working just fine.
Sensors rarely fail.
My '94 has all original sensors except for O2s, at 300k I will replace them again soon

O2 sensors use chemicals so do wear out same as batteries do, should be changed at 125k-150k.
CPS and TPS sensors can wear out although it is not common, CPS synchronizer, can wear out on the 4.0l but far more common on the 3.0l Vulcan