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4.0L OHV & SOHC V6 Tech General discussion of 4.0L OHV and SOHC V6 Ford Ranger engines.

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  #1  
Old 04-17-2006
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4.0 SOHC Swap Progress

Since there has been some interest, I thought I would start a progress thread.

For those who haven't caught it yet, I am in the process of swapping a 2001 4.0 SOHC and transmission into my 1997 2.3. I've had the donor truck stripped and gone for a few weeks but have been too busy to give up my DD to the project so I haven't been able to really get into the swap until this weekend.

My plan was to get the new engine and transmission in this weekend and spend the beginning of next week working on wiring and such, but I ended up having trouble getting the new engine mounts, which wouldn't have happened if the jy knew the difference between a 3.0 and a 4.0, and so I have been delayed. I should be able to get the mounts on Monday and the engine swapped in shortly after that.

So far the only snag I have hit is with a radiator. I finally found a 95-97 4.0 OHV radiator nearby and I should be getting it when I go to get the engine mounts...assuming it will work. I have seen a few people swap this engine into a 97 and all used a stock radiator so I am assuming that the OHV radiator is the one they used. The radiator from the donor truck is too wide and a radiator from a SOHC Explorer is as well...which is a shame since that "heavy duty" radiator they put in them would be really nice to have...

I was originally worried that the A/C condenser from the donor truck would not fit either but it looks like it will fit with little or no problem. Once my parts from Summit get here I should have a power steering pressure hose fabbed up and after that will come a whole bunch of wiring...which is actually a part I enjoy so I'm not worried about that. I will also be taking the opportunity to wire all of the various additions such as EATC, OHC, Efan into the factory harness to clean things up. I am also going to be putting the one-piece drive shaft on from the donor to replace that silly two-piece thing Ford originally gave me. Once I have a truck that runs again I will also be swapping on an Explorer 8.8" rear.

It looks like it should be relatively painless to finish...as long as there are no more surprises...

I think that's all I have to say for now...its late.

Oh yea, and I'll post some pictures tomorrow.
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Old 04-17-2006
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Why don't you post the pictures now man? I've seen them, I think the world needs to know!
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Old 04-17-2006
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Are you staying with a manual transmission or moving to an Awefulmatic?
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Old 04-17-2006
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He's got the manual out of the donor truck.
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Old 04-17-2006
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Nice progress for sure, I wouldn't mind seeing some pics.
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Old 04-18-2006
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Found a radiator that works today out of a 96 Ranger 4.0 OHV. Even better its the "super cooling" radiator or whatever Ford called it. I think I'll use the transmission cooler built into it for an oil cooler eventually...but either way it will be nice having the larger radiator during the summer.

Ended up having to go to Autozone for the engine mounts and the Ford dealership for the brackets that go between the mounts and the engine block. That stuff will be here Wednesday...hopefully...so I'm going to spend tomorrow getting as much wiring done as I can while everything is out of it. I will probably start swapping the fuel tanks and lines as well.


Transmission after being dropped out of the donor...


Empty donor...


Empty donor interior...


Engine after being pulled...needs some cleaning...


How many trailer loads does it take to get rid of a chopped up Ranger? Heres load one of two...(cuttting torches are fun)...


My truck with a 2.3...


The next morning...my truck without a 2.3...still needs to have a few things removed...


I found the source of that annoying noise coming from my engine at idle...heres the pieces of my passenger side engine mount...


The Ranger parts warehouse I am starting...


More Ranger parts (yea, its easier to just take out the A/C system as one piece than to discharge and recharge it)...


My old engine and transmission...




I think that's all I have to say and show for now...
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Old 04-18-2006
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Awesome pics...man this is goin' to be a pretty cool truck. Perfect time for some JBAs on that beast.
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Old 04-18-2006
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Quote:
Originally Posted by Fx4wannabe01
Awesome pics...man this is goin' to be a pretty cool truck. Perfect time for some JBAs on that beast.
Agreed, def put them on now or its going to be a pain once the motor is in. Cant wait to see how it turns out.
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Old 04-18-2006
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Boy those pictures bring up some mixed emotions... Hahah it's looking great man! I told you it would be a good time for headers!
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Old 04-18-2006
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Got a call from Ford...they don't have the engine brackets. So far none of the yards around here will sell them to me if they have them...and I haven't found them at a u-pull yet. Anybody have a pair of brackets for a 95-97 4.0 OHV or live near a yard with that kind of Ranger? Its the part that goes between the rubber engine mounts and the block.
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Old 05-19-2006
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Wow...has it really been four weeks since I last posted an update?

So...the last four weeks...

Unfortunately life caught up me and between school and other obligations I had very little time to work on the truck...which wasn't too much of a waste since I was lacking parts anyway. After about five failed attempts (wrong brackets being shipped, etc) to get the engine mounting brackets I drove up to a yard near Atlanta two weeks ago and pulled them. I finally was free to work on it again last weekend and as of this moment it will turn over and after I add a little bit of wiring tomorrow it should run.

Contrary to what I have read elsewhere, the oil pan does hit the engine crossmember on the passenger side. I had plenty of room to shift the engine towards the driver side so I drilled new holes in the mounting brackets and added a .25" steel plate between the passenger side mount and the block. I probably managed to move it over .5" which seemed to do the trick. The engine sits a little high on the passenger side, but I can't lower it because of the oil pan and I can't raise the driver side because the hood hits. The difference is only maybe .25"...which drives the perfectionist in me insane...but the slight rotation moves the shifter slightly closer to the driver which is kinda nice. I will probably go back and add something to keep the engine from rotating too much since clearances are a little tight.

I am a little concerned about the clearance between the steering box and the a/c compressor. There's maybe .5"-.75" between the compressor and where the fittings need to go on the steering box so that will be interesting.

After adding EATC, an OHC, keyless entry, and power windows/mirrors/locks, the perfectionist in me wanted everything wired into the factory harness as it should be since all the parts I used were factory parts. As a result of the changes I needed to make for the swap and the changes I wanted to make as an electronics nerd, I have probably added/removed/modified/repaired 90% of the wiring in the truck. Lotsa work...but at least there are no silly butt splices in MY truck.

I know...pictures. I have a few I'll post soon...but I didn't take many during the process because Sony hasn't fixed my P&S yet and there's no way I'm dragging the SLR out while I'm working.

Oh yea, if a grinding disk shatters near your arm it will leave a mark. Same goes for drill bits.

It's late...I'll post more later...
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Old 05-19-2006
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how many miles are on the doner engine and tranny?

thats awesome that you have it turning over, good job!

still gonna swap in an expo 8.8 after all the time and work?
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Old 05-19-2006
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Hmmmmmm.... sounds like fun! can't wait to see that thing fly down the strip in holt...hint, hint.
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Old 05-19-2006
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I'm really looking forward to seeing your truck get up and running Stephen! And I want to see this silly wiring harness you're so proud of!
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Old 05-19-2006
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lol awesome read. cant wait for more pics.
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  #16  
Old 05-19-2006
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Finishing some wiring this morning


New steering wheel and column


Dash wiring










And the important picture...under the hood this morning...
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Old 05-19-2006
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Quote:
Originally Posted by KARPE
how many miles are on the doner engine and tranny?
70k-ish...Kyle's (Gearhead61) old truck was the donor

Quote:
Originally Posted by KARPE
still gonna swap in an expo 8.8 after all the time and work?
Definitely
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Old 05-19-2006
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Quote:
Originally Posted by rolla_guy72
Hmmmmmm.... sounds like fun! can't wait to see that thing fly down the strip in holt...hint, hint.
Not until the supercharger goes on...duh
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Old 05-19-2006
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Man that wiring gives me a headache just looking at it! You are a brave soul! It looks awesome though I can't wait to see it all up and running!

You thought anymore about selling me your phone!? I'm working on getting Phoco running on my carputer and getting it imbedded with the right front end.
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Old 05-19-2006
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Quote:
Originally Posted by D.
Are you staying with a manual transmission or moving to an Awefulmatic?

Hey!!! Watch it!!!
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  #21  
Old 05-20-2006
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You need an engine like this:

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  #22  
Old 05-21-2006
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There's nothing quite like starting up an engine for the first time after an engine swap...at 2am...with nothing but headers on for exhaust

It lives...
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Old 05-21-2006
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Woohoo!!! I bet Matt's happy...lol!!!

Sweet, I gotta work till 330 I'll swing by and check it out!!
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Old 05-22-2006
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Sweet dude, that must of been a GREAT feeling!

Did you rebuild the motor? And what do you have on it as far as bolt-ons and what not? I see a supercharger is in the mix, that would be badass!
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Old 05-23-2006
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Quote:
Originally Posted by 01xltranger4x4
Sweet dude, that must of been a GREAT feeling!

Did you rebuild the motor? And what do you have on it as far as bolt-ons and what not? I see a supercharger is in the mix, that would be badass!
It's going to feel REALLY good when it gets back on the road...hopefully within the next 24 hours or so. The power steering and temporary exhaust SHOULD be done tonight so after I put the bed back on and put the various fluids back in I'll be out driving to see how many parts fall off.

I haven't really touched the engine...my main concern has been just getting it in there and running. The power difference between the 2.3 and 4.0 will probably keep me happy for a little while anyway. I've got an efan on (I think a custom controller will be my next project) and I'm heading to the shop for Magnaflow exhaust as soon as it is driving. I thought about headers while it was out, but I don't really see any benefits to justify the cost at the moment.
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