General Technical & Electrical General technical and electrical discussion for the Ford Ranger that does not fit in any other sub-forum.

4.0 Swap Issue

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Old Jun 4, 2024
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Jhemmin1's Avatar
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Joined: Jun 2024
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From: Riverton, Wyoming
4.0 Swap Issue

Hey all,

Long time reader, first time poster here. I have exhausted the knowledge I have on my project, and was hoping to gather some thoughts and ideas to hopefully give me some direction!

I have a 1998 Ranger that was my first pickup, purchased from my grandfathers estate when he passed. It is very sentimental to me. Originally it was a 3.0 Manual 4x4, however right after I left college the 3.0 ate a valve. I decided in my young ambitious ways that I would swap the powertrain rather than put time and money into the 3.0.

I ended up acquiring a 2003 4.0 auto ranger that had been rolled at low miles, and robbed what I needed to begin the swap. I sourced an '03 manual trans, swapped in the motor, 8.8 rear, trans, t case, etc. And was able to rebuild the harness from the 3.0 to mate up to the 4.0. I also sourced a 1998 4.0 computer and installed it. I spent the next couple years researching the swap and everything necessary, slowly piecing everything together with help from these forums, and at this point the truck is complete and ready to try and get back on the road.

Here is where my current snag is- after I drained the old fuel and tossed in a new battery, when I attempted to fire the truck up, everything lights up as normal, fuel pump and relay work as intended, but the starter just clicks... No spin. The starter is brand new, i removed it and tested that it is functioning properly. When turning the ignition, you can feel the starter relay click. It seems to me the battery cables get pretty warm to the touch after attempting to start. I have double and triple checked fuses, relays and wiring, and everything seems to be correct, so I am at a bit of a loss and unsure where to go from here.

I really hate the idea of bringing the project right to the finish line and then needing to take it somewhere for help, but am defeated enough at this point to where I have considered it. I figured it was worth stopping here first, and gathering some thoughts. Being that I am running a '98 with a '98 computer, I figure PATS should not be a culprit despite the motor being from an '03, but as I am no expert I figure its worth mentioning. Any help you could provide would be greatly appreciated, and I wont be offended if you tell me I have completely botched this one. I appreciate your time in reading this, and look forward to seeing what the community has to say!
 
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