Yes, I am new here and have enjoyed reading the posts here over the years.

My question is this: can an NPI 5.4 engine from 1998 Expedition go in 1999 PI 5.4 F150 replacement and what all would have to be changed?

I cannot use the wiring harness from the 1998 NPI and I have to use the one from the 1999 PI. (Without rewiring one thing or two on the NPI harness)

Is there a way to use the Butterfly lower or can I just place the PI lower on the NPI upper and use it that way?
I don't know if it is Romo or Windsor ( I do know that the Romo had the 8 bolt flywheel and the Windsor had the 6 bolt or something like that).

A little history: My 1999 5.4 oil pump went out and locked the PI engine up (little over 400.000 miles on it) and I have a rebuilt 5.4 NPI engine with less than 80,000 on it and it is an 8 bolt flywheel.

Note: It came out of and expedition Eddie type 4x4 and I cannot tell the true engine type as it was a remanufactured engine.
(On the plate is this. L5497W2TA RO7270408 980890468 429-03-30-98 5.4L) the heads are the RF-F75E-6090-C20A NPI type.
(Had to buy the Expedition 4x4 Eddie type because I got it all for cheap) delivered to my place.
It drove good and all that, but I wanted it for the 3.55LS gears, trans, engine, and the transfer. The engine has set for around five years maybe a little more, but I have cranked it up and moved it around so I know it is good.

Both engines have the metal upper intakes, but the NPI has a Butterfly Lower and the PI engine has just the open lower. The NPI also has the water temp with waterline by the thermostat. The NPI engine also has a better oil system with the lines that run to the frame behind the bumper to remove the filter easier and the other water lines coming from the oil housing.

So has anyone did this and what do I need to do to make it work?
Thanks ahead.

 

Non-PI heads require non-PI intake and exhaust manifolds.

I'd think about pulling the PI heads off your dead engine, see if they can be cleaned up or rebuilt, and put them on the non-PI engine along with the PI manifolds.

 

Thought about that as well, but the PI engine has over 4000,000 miles on those heads and I know they would need rebuilding.
I am lucky that both have the metal upper intakes and not the plastic ones.

I guess I am the guinea pig for this change type.

Looking at all of the writeups out there that is about what Ford did to make a 5.4 a PI.

Thanks for the reply as it gives me more to think about.

 

I know about the PI manifold. I put an aluminum upper and lower on my 2001. Dorman aluminum lower.

The aluminum upper PI manifold only came on the 1999.

You need the pi heads, and intake and exhaust manifolds.

 

I have a complete 1999 5.4 PI engine that has over 400,000 miles on it when the oil pump went and locked it up.

The other engine I have is a 1998 5.4 NPI engine with less than 70,000 miles from an Expedition.

From what I have seen and know so far I have two choices to make.

(1) Put the 5.4 NPI engine in and hope for the best with some mods.

(2) Put the 5.4 NPI engine in and place the heads, intake, and exhaust off the 5.4 PI engine on it and hope for the best.

Either way, wifes said I had better get HER garage cleaned up fast.

 

Get the pi heads rebuilt. Put them on the non pi block.

Don't be lazy, or a cheapskate.

 

Over 400,000 miles! Impressive!

 

It's my all-around ride from mudding, hunting, honey-do this type of truck.

I got mad at the truck more than once, but I love the body of this truck.

Put the mechanical finger on to set the front axles to lock (vac will leave you when you need it the most for 4x4) and it pulls great after I built a 9.75 rear-end for it and a front end LS.

This is the first major let down of this truck after all these years together.

Never had the spark pug blowout or any major thing.

Now I didn't baby it either and have put it to bed wet before and that is why it has over 400,000 miles on it.
I am behind a friend of mine who has the same year but with the 4.6 and he has a little more than me of about 4000 miles last time I checked.

More than one person has tried to buy this truck and my youngest grandson has told the family if something happens to me he gets the truck.

 

How many times the trans has been rebuilt?

 

It was gone into at about 105,000 miles by a friend who builds trans and transfers. He worked his magic on it and it has not been out since.
They have about 300,000 miles on both of them. No leaks or anything from either of them.

I have dropped the trans and transfer as he is going to look at both and see what needs to be done to each. (I think he just wants to see how well he built them and then gloat at me)

I have the other two I have ready to go in as soon as I get ready for the engine install.

 

I am cheap, but my wife wants her garage back I have been told.

From what I have read and all that the horsepower would be about 35 more at the flywheel and a pickup of 1.5 compressions.

Not a lot for the money, but if I do that. I would need to find the phone number of a guy in AL that owes me a favor for setting up his 1972 horse fastback, I will have him set the ford computer up on this truck. He is one of those people.

 

Well, I just found out by taking the lower intake off the NPI intake that it is like the upper intake ports ROUND.
Going to change the gasket on it anyway just in case my heads are not ready and I have to use the NPI system.

There goes my thinking that a lower NPI intake and a PI lower were the same. Scratches head and throw's a wrench through the garage.

Anyway, I have to rebuild the wiring harness plugin for the crank sensor that a dog and a rat tore off. (Bulldog sees a rat, bulldog gets a rat and sensor wiring, bulldog shows owner his good deed). Owners want to kill man's best friend.

 

From everything I have researched the swap from NPI to PI needs every component. Heads, upper and lower intake as a set. It is a hard line Ford drew in the sand where they changed how everything was made and assembled all at once.

The bulldog meant well :^( but that doesn't diminish the amount of work that now needs to happen

 

just sell what you have and buy the right engine and drop it in......

doesn't seem cheaper now, but will be better in the long run.....

ASK me how I know........

 

Yep, Buba the bulldog is an English/Pit cross and he reminds a lot of that Bugs Bunnie cartoon where they say: which way did he go, George.
He is just one of those laid back dogs that you wouldn't know he was there type until it was too late or something like that. He does for some reason hate Rats and Cats.

Now I have had to order a new connector to splce into the harness, but the price was just about $10.00 for it.

In case someone else needs this part number for a crank sensor plugin and wiring to harness that works on 4.6L and 5.4L.

AIP Electronics

Manufacturer Part Number: WH1014

Interchange Part Number:1P1261 S819 645-570

UPC:025093040528