Bob's swap project: Level II meets 5.0L
#1
Bob's swap project: Level II meets 5.0L
It all started with a lowball offer on an eBay engine...
Well, actually it started much earlier when I had my 2000 Trailhead and wanted to do a V8 swap. That never happened but the the 03 Level II will have one in the next few weeks!
Here is the 5.0L Explorer engine in all of its junkyard glory:
And here's a mock up of the progress. There's more to do but it's almost ready for final reassembly:
Well, actually it started much earlier when I had my 2000 Trailhead and wanted to do a V8 swap. That never happened but the the 03 Level II will have one in the next few weeks!
Here is the 5.0L Explorer engine in all of its junkyard glory:
And here's a mock up of the progress. There's more to do but it's almost ready for final reassembly:
#2
The parts list … so far
New parts:
Manual transfer case linkage
Conversion U-joint
Radiator
Radiator hoses, heater hoses, bypass hose
Gatorback serpentine belt
Power steering pressure hose
Magnaflow dual in/dual out muffler
Melling M68 oil pump
FRPP oil pump drive
FRPP GT40 intake manifold insulator/spacer
Ranger PRNDL display
Transmission shift cable
Throttle cable
Rear main seal
Valve guide seals
Gaskets
Lots of nuts, bolts, washers, paint, fluids
New Explorer 5.0L engine take-off parts:
Timing cover and front main crank seal
Water pump
Crank pulley
Crankshaft Position Sensor
Coil packs
Ignition Wires
Synchronizer/Camshaft Position Sensor
Injectors and fuel rails
EGR, EVR and DPFE
Used parts:
99 Explorer 5.0L Engine/PCM/harness
99 Explorer 5.0L exhaust pipes and cats
99 Explorer 5.0L 4R70W transmission
99 Explorer 5.0L A/C manifold and hoses
96 Explorer 5.0L engine oil cooler
97 Explorer aux transmission cooler
99 Exolorer PATS Module and transceiver
98 Explorer column shift parts
99 Explorer 5.0L speed control cable
97 Mountaineer center console
98 Explorer Message Center/trip computer
03 F150 BW4406 manual transfer case
03 F150 front driveshaft
03 Expedition/Navigator slip yoke
96 F150 transmission mount
New parts:
Manual transfer case linkage
Conversion U-joint
Radiator
Radiator hoses, heater hoses, bypass hose
Gatorback serpentine belt
Power steering pressure hose
Magnaflow dual in/dual out muffler
Melling M68 oil pump
FRPP oil pump drive
FRPP GT40 intake manifold insulator/spacer
Ranger PRNDL display
Transmission shift cable
Throttle cable
Rear main seal
Valve guide seals
Gaskets
Lots of nuts, bolts, washers, paint, fluids
New Explorer 5.0L engine take-off parts:
Timing cover and front main crank seal
Water pump
Crank pulley
Crankshaft Position Sensor
Coil packs
Ignition Wires
Synchronizer/Camshaft Position Sensor
Injectors and fuel rails
EGR, EVR and DPFE
Used parts:
99 Explorer 5.0L Engine/PCM/harness
99 Explorer 5.0L exhaust pipes and cats
99 Explorer 5.0L 4R70W transmission
99 Explorer 5.0L A/C manifold and hoses
96 Explorer 5.0L engine oil cooler
97 Explorer aux transmission cooler
99 Exolorer PATS Module and transceiver
98 Explorer column shift parts
99 Explorer 5.0L speed control cable
97 Mountaineer center console
98 Explorer Message Center/trip computer
03 F150 BW4406 manual transfer case
03 F150 front driveshaft
03 Expedition/Navigator slip yoke
96 F150 transmission mount
Last edited by V8 Level II; 10-09-2007 at 07:54 AM.
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This is the modified F150 shift linkage mounted to the Explorer transmission extension housing. To get some extra clearance, I reversed and rewelded a pin in the linkage and cut almost 3/4" off the factory mounting bosses on the extension housing. Then I drilled the holes deeper and retapped the 14mm threaded holes for 5/8" x 1 1/4" NC bolts. This mod will improve the clearance from the F150 T-case linkage to the smaller Ranger transmission tunnel.
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#16
Originally Posted by Gearhead61
Does the auto tranny require any inputs from the Ranger's computer? Or will there be any wiring difficulties for the transmission? And why did you choose an automatic over a manual transmission?
The overall wiring is not bad. Besides some minor pinning differences, there are just a couple of funnies with the speed sensor and the A/C WOT cutout. At least, that's all I know about going into the project....
I would have preferred a manual but there are not many possibilities that will work easily with a late model Ranger 4x4 swap. Each of those manuals has a problem or two, so I decided to use the auto instead. The Explorer 4R70W is a decent trans, it bolts direct to the 5.0L engine and the F150 t-case and it works perfectly with the stock Ex 5.0L calibration.
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#19
Originally Posted by Rockledge
Bob, do you foresee any issues using the '99 Explorer PCM with your Ranger '03 GEM and PATS system? Are all the components in the so-called "Module Communications Network" going to be compatible?
#20
Originally Posted by KARPE
were you running with a bama tune?
can you use the same equipment( bama tuner) with new programs on the new set-up?
can you use the same equipment( bama tuner) with new programs on the new set-up?
The flash tuner hardware would be the same but a completely different calibration would be needed for the Explorer vs the Ranger. I believe that Doug does cals for the Explorer PCMs too.
#21
Wholey cow batman! I figured I'd see a thread like this someday. That's pretty bad-*** Bob..
I only echo the manual vs auto comments. 'Tis a damned shame you can't stick w/ a manual. But then IIRC the Ex was never packaged w/ both the V8 and a manual trans, was it? And I imagine that V8 would probably make short work of the factory manual trans our trucks come w/... or more likely the clutch.
At any rate, very cool.
Waaait a second. You are fitting a BW4406 from an F150?! Isn't that a full-time/AWD t-case? Does this mean you'll have both full (AWD) and part-time (locked) 4x4 operation when done. Now I'm seriously jealous!!!
I only echo the manual vs auto comments. 'Tis a damned shame you can't stick w/ a manual. But then IIRC the Ex was never packaged w/ both the V8 and a manual trans, was it? And I imagine that V8 would probably make short work of the factory manual trans our trucks come w/... or more likely the clutch.
At any rate, very cool.
Waaait a second. You are fitting a BW4406 from an F150?! Isn't that a full-time/AWD t-case? Does this mean you'll have both full (AWD) and part-time (locked) 4x4 operation when done. Now I'm seriously jealous!!!
#22
Originally Posted by NHBubba_Revisited
Waaait a second. You are fitting a BW4406 from an F150?! Isn't that a full-time/AWD t-case? Does this mean you'll have both full (AWD) and part-time (locked) 4x4 operation when done.
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#24
Originally Posted by NHBubba_Revisited
Ah. A quick google suggested that it might be.. but didn't have any definitive info.
- Manual like mine
- Electric Shift-on-the-Fly
- Electric SHift-on-the-Fly with Torque-on-Demand
Originally Posted by NHBubba_Revisited
..in that case you're a fruit for throwing out a perfectly good Mazda 5-speed manual trans w/ its nearly indestructible clutch and slave cylinder throw-out bearing assembly for that half baked slush box!