WOW it's been 4 years already since I first came here.

First off I want to Thank everyone here for their help. I especially want to thank those who helped me 4 years ago buying, info, install questions, etc of the Powerdyne Supercharger on my 4.6L truck.
Especially members Onelowf and Tarajerrme.

Since last time here we have been messing with Jeep Cherokees and supercharging them and off roading and autocrossing them. Here is what we have been up to- JeepM62SuperchargerKit.blogspot.com

Now our attention is back on the F150 with the Powerdyne SC which has been performing well for the last 4 years. We need to tow a trailer and Jeep to offroad sites and are looking for a bit more power.

We recently developed a small exhaust leak and it looks like the passenger side manifold is leaking or cracked. Instead of replacing, time to upgrade. So it looks like headers, IDK maybe OBX long tube or JBA shorties and new cats. So while the headers are off why not upgrade some more. We are looking for more overall power, better economy and towing. 300-325rwhp range.

HEADS-
Being a '98 we have NPI heads. We want to upgrade the heads. Ideally we would like to use Trick Flow Twisted Wedge with 44cc chambers. These will increase compression to 10.0:1 from 9.4:1. We will also finally get a proper dyno tune to keep everything safe. We will use the stock cams and keep the powerdyne SC. The headers and heads will probably lower the boost but that is OK if it is making more power. I want to keep the tall truck intake manifold and not use a mustang manifold. I only need power to 5000 or so.

So my question is- What intake manifold do I need to use? Can I use my stock '98 NPI tall truck intake on the TFS heads? Which gasket do I use, NPI or PI?
If I need a PI truck intake, which year and model do I need to find?

The final plan we are after is TFS Ported big valve heads with stock cams and truck long runner intake manifold with the powerdyne SC and headers.

Thanks and Happy New Year to everyone.

 

I hate to be the bearer of "bad" news by adding a few more dollars to your cost


but yes, you will need a PI intake manifold, I know the '01-up F150's had the PI 4.6

 

Thanks. That is what I was beginning to think as I started searching more.

A lot of guys want to put the PI intake on the NPI head and ran into issues with the water jacket. Solutions from RTV, weld intake, weld head, spacer plates like $350.

I have found the Dorman plastic upper intake that looks like it is PI and then there is the Ford aluminum PI upper intake manifold.

Is the lower intake manifold the same for NPI and PI uppers? Any year differences?

Does anyone have a truck PI upper intake manifold for sale?

Are the 4.6L and 5.4L upper PI intake manifolds the same?

 

After more searching and picture comparing...
the 4.6 and 5.4 heads interchange
the 5.4 upper intake is wider
the 4.6 and 5.4 lower intakes ? are the same

Which year/engine used a butterfly valve in the front of the lower intake?

 

The 5.4 and 4.6 PI heads are the same and you would still need the PI intake for a 4.6. Check around for 2001 4.6 truck manifold. The reason the 5.4 intake is different is because the deck of the block is I believe 15mm taller hence wider and longer stroke. Personally I would stay away from plastic manifolds due to long term leak issues. Typhoon makes an intake for mustangs that could be used but you would loose torque with the shorter runners.

 

Getting parts-

-found on ebay '01 4.6L f150 intake manifold $65, just needs a cleaning
-Trick Flow chrome moly head bolts from Summit
-ordered all the gaskets from RockAuto
-ordered TFS Twisted Wedge Heads and OBX headers, waiting on shipping

 

TFS PI heads on non-PI 4.6L truck engine

PROJECT COMPLETED !!

Bought new TFS 4.6L heads 44cc
TFS Chrome Moly head bolts
BBK shorty headers
Flowmaster high flow cats and downpipe
Metal '01 4.6L PI truck long runner upper intake manifold
'04 4.6L PI plastic lower intake with 'power flapper valve' in front
re-used stock under intake water line
MLS head gaskets
reused my good NPI cams
rebuilt PowerDyne supercharger by 928 Motorsports
New motorcraft O2 sensors, NGK spark plugs, synthetic oil
new starter, new water pump

Mustang Dyno- 2nd gear, auto, 33"tires, custom tune
pulls to 5200 rpm, 6 pounds boost most everywhere, 7 pounds at 5000 rpm

+70RWHP and +60RWTQ

next-
-3" cat back Magnaflow Exhaust and single 4" side tip
-Meth/washer fluid injection

 

FYI short headers are worthless for performance gains. Long tubes are dyno proven to give 15-30 hp. Short give nothing.

 

Had them, tried them, hammered them and the Long Tubes didn't fit.
I think that the TFS heads might have move the exhaust ports slightly.
I didn't try the long tubes on stock heads.

The stock log manifolds and 100k+ cats- flow the worse.
Don't discount the shorties and high flow cats.

BBK shorties and Flowmaster high flow cats vs. stock log manifolds and cats.
Not a tough choice.
I had an exhaust leak and was not going to replace with stock manifolds and cats.

I would be interested in back to back dyno results on stock vs. shorties vs. long tubes. I can't find any supporting evidence.

 

I know there was a board member who did all three stock long and short built 54 if I recall correctly. Only the long tube increased HP.

 

Picked up the truck today to bring home.

Tuner spent considerable time tuning the trans. Increasing the line level pressure, decreasing the downshift rpm, delaying the upshift to 3rd and 4th.
Made a huge difference in drivability.

Power wise, naturally aspirated/out of boost feels better than before with 2-3 pounds boost. Accelerating pulls way harder. Put your foot down to pass, 60-80 comes very quick. Will easily smok'em from a stop.

Big difference, well worth the time and money.

3" Magnaflow cat back exhaust coming soon. That should help compared to the 2.5" and flowmaster muffler.

 

As far as I can find, this is the only NPI to PI head swap on a 4.6L truck using TFS Heads.

 

The more I drive the truck, the better it feels.
The tune is a bit rich on cold start, gotta fix that, otherwise doing great.

The 1 point extra compression and the better flowing heads and intake manifold really wake up this engine. Off idle/stop sign acceleration is soo much better. Pulls hard, smooth. Can easily smoke the tires.
Doesn't feel like it is breathing/wheezing thru a straw any more.

Definitely runs better in the cold night air we recently had. Gotta get the Meth/washer fluid injection hooked up and working.

Thought about a 5.4L swap in the distant future for an easy 20% jump, but for now, I am totally satisfied. This was one of the best upgrades that I have done.

Still have to do the 3" Magnaflow cat back exhaust upgrade from the 2.5" flowmaster exhaust on there currently.

 

More...

Last night 70* ambient, normal IAT 95* idling, about 110* on acceleration.

After 40-80mph and 3-4x 60-80mph, 'Charge IAT' spiked to 135* and would go DOWN to 120-123*under WOT with 5-6 pounds boost. Didn't want to go over 80mph. It was getting colder the longer in boost.

Very pleased with these Powerdyne SC non-intercooled charge IATs.
Will monitor some more to confirm all these numbers and trends.

Have Meth/washer fluid injection ready to hook up. Might be able to get charge IATs down to 10-20* over ambient.

 

The water/meth helps considerably.i usually use boost juice and the stuff has jumped a good 40% over the last year price wise.

I also use the winter washer fluid and a bottle of heat with the same or similar effect. I occasionally use rc nitro fuel 30% in a 2/10 ratio with a seat of the paints effect!

Cool build btw. How is she doing for towing?