One thing that I just realized is that the 4X4 4.0 SOHC has a balance shaft.(Don't know why, but it does)
Is that anything I need to be worried about, or is that all mechanical?

 

Yes, it is purely mechanical. The 4x4's had it for NVH reasons but, as I understand it, the difference is minor with or without the shaft.

I think I heard somewhere that the newer 4.0's don't have the shaft at all, regardless of whether the truck is 4x4 or 4x2. I can't verify that because my latest Ranger shop manuals are 2002 and 2003. They both show the 4x4 as using a balance shaft.

 

Hey Bob,

I was reading about your engine conversion on another Ranger site and I seen where you were talking about EVTM and VSS.
Is that something I need to be worried about?

 

EVTM = Electrical and Vacuum Troubleshooting Manual used by Ford dealers. The equivalent of the EVTM for 99+ Fords is called the "Wiring Manual". There is a different one for each year and vehicle line.

VSS = Vehicle Speed Sensor or Vehicle Speed Signal.

If you stay with a 2004 Ranger, PCM, engine, harness and cluster, the VSS should be no problem. I THINK the same is true when using 2005~2006 parts in a 2004. Other years could have issues or maybe not.

 

Thanks for answering my question Bob.
I feel better about this now.

 

I don't know how true this is, but it came from a pretty reliable source. I was just told that there's a card behind the 2004 + clusters that stores the mileage ... if that's the case, then I shouldn't need another wiring harness and a PCM aka ECM.
Does anyone here know anything about this?

 

The cluster stores the odometer in 2004+ Rangers. If you are changing engine size, the PCM and engine harness are different, even within the same year.

 

Ok, I'm just gonna bite the bullet and buy a 2005 wiring harness and PCM but I'm worried about hooking the connectors up on the injectors. Do most salvage yards label the connectors? If not, it's gonna be a guessing game.

 

they only go in one plug

 

Just remember that you are in uncharted territory here and there is no absolute guarantee that the 2005 4.0 harness will fit a 2001, 2004 or any other year 4.0 except 2005 without modification. The same goes for the 2005 harness in a 2004 truck.

The harness is laid out to make the shortest possible runs to each injector so it would be difficult to get it wrong. Besides that, each injector has a unique color code on one of its two wires, the one that the PCM grounds to fire it.

Another thing: carefully check each of the injector connectors for missing lock tabs before buying. They tend to get crispy from engine heat and may break off easily when removed. Replacement connectors are available from Motorcraft but they are something like $30 EACH.