04-13-2015, 12:25 PM
Last edit by: IB Advertising
Interested in swapping your 4.6 to a 5.4? This thread lists several problems you may run in to. The most common are:
Read the full discussion below to find out how to deal with the common issues.
Read the full discussion below to find out how to deal with the common issues.
4.6 to 5.4 Swap Notes
#316
08-27-2016, 01:18 PM
My instructions only cover replacing the 4.6 engine with a 5.4. 1997 to 2004. This is 8 years of production. During those production years quite a few changes were made. Some of these changes included the wiring harness in the engine bay. I made no effort to check the pinouts on every connector to insure they would be compatible through out the years. The simple solution would be to remove the 4.6 and install the 5.4 using the existing 4.6 harness.
If you transplant the 5.4 with tranny, t-case and PCM you may encounter problems with the GEM module. It controls a multitude of components including 4.4 activation. It is located above the fuse box in the dash. Your 5.4 has a 9.75 rear differential. It is bigger than the 8.8 in your 4.6 truck. That means the driveshaft is shorter.
If you transplant the 5.4 with tranny, t-case and PCM you may encounter problems with the GEM module. It controls a multitude of components including 4.4 activation. It is located above the fuse box in the dash. Your 5.4 has a 9.75 rear differential. It is bigger than the 8.8 in your 4.6 truck. That means the driveshaft is shorter.
#317
09-01-2016, 12:37 AM
I think this is doable:
Current Truck: 1998 F150 4.6L 4R70w Buying a wrecked 2004 Expedition 5.4L 4x4
Questions:
1. My 1998 4.6 Engine ecu will run the 2004 5.4L as long as i swap over the coil bank setup and reprogram.
2. The 2004 5.4 will mate up to my 1998 4r70w with no issues?
3. What needs to be swapped from the 4.6L to the 5.4L on the intake side? (full upper intake)?
4. What else am i missing?
Current Truck: 1998 F150 4.6L 4R70w Buying a wrecked 2004 Expedition 5.4L 4x4
Questions:
1. My 1998 4.6 Engine ecu will run the 2004 5.4L as long as i swap over the coil bank setup and reprogram.
2. The 2004 5.4 will mate up to my 1998 4r70w with no issues?
3. What needs to be swapped from the 4.6L to the 5.4L on the intake side? (full upper intake)?
4. What else am i missing?
#318
10-05-2016, 08:49 PM
First I was curious if anyone knew if a 5.4 Triton out of an 07 F-150 would fit and of course properly work in 97 F-150. I know i have the 8 bolt flywheel. and I know it would be fine for the tranny is there any other problems i would have?
Also, I have the 4R70W transmission, are you saying that the torque coming from the 5.4 would be too much for the tranny to handle? and would i also need to upgrade to a 4R75W? Or is there another fix that could be done?
I'm also not sure if the 07 would have a different configuration for the way plugs are, such as if the plugs are computer controlled fully or if it would still have a distributer like my 4.6 right now.
Also, just as a side note. would you believe that if i can find the a simple fix for my 4.6 right now, would it be worth it to just sell the truck? I'm in about $8,000. And if i could fix the truck relatively cheap would it be better to sell it, or keep it till the engine blows?
Also, I have the 4R70W transmission, are you saying that the torque coming from the 5.4 would be too much for the tranny to handle? and would i also need to upgrade to a 4R75W? Or is there another fix that could be done?
I'm also not sure if the 07 would have a different configuration for the way plugs are, such as if the plugs are computer controlled fully or if it would still have a distributer like my 4.6 right now.
Also, just as a side note. would you believe that if i can find the a simple fix for my 4.6 right now, would it be worth it to just sell the truck? I'm in about $8,000. And if i could fix the truck relatively cheap would it be better to sell it, or keep it till the engine blows?
#319
11-07-2016, 11:15 AM
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Almost finished swapping '98 5.4 into a '98 that came with a 4.6. Two suggestions.
My exhaust guy said the exhaust hook up is easier using the 4.6 manifolds.
Check to see if anyone does ecm tunes in your area. I did a lot of asking and running around to different shops in the Battle Creek area with no luck. Ended up ordering an SCT x4 from 5StarTuning.com. It is on it's way now. (About $440 with 3 tunes and shipping.) When it arrives I will download the "strategy" from my truck via OBD2 port and email it to 5 Star. They will write tunes and email them to me for download to the truck. It starts and runs on the original tune, but has bad drivability issues.
My exhaust guy said the exhaust hook up is easier using the 4.6 manifolds.
Check to see if anyone does ecm tunes in your area. I did a lot of asking and running around to different shops in the Battle Creek area with no luck. Ended up ordering an SCT x4 from 5StarTuning.com. It is on it's way now. (About $440 with 3 tunes and shipping.) When it arrives I will download the "strategy" from my truck via OBD2 port and email it to 5 Star. They will write tunes and email them to me for download to the truck. It starts and runs on the original tune, but has bad drivability issues.
#320
11-29-2016, 02:20 PM
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5.4 swap
The 5.4 Swap is quite an improvement over the stock 4.6 engine. It wasn't quite as hard as I originally thought that it would be. However it should be noted that when you evaluate the truck, pay close attention to the 4r70w transmission.
My swap made it about 7K before it found a weak forward drum so I am preparing to rebuild the unit now.
I have the ATSG Update manual for the 4R70W. Does anyone on this site have a pdf of the Factory manual for this transmission? I don't mind buying a manual, however the only thing that I can find is the ATSG manual for the AODE and it may not have the precision measurements that is needed for a professional rebuild of this unit.
Thanks for all the help on this site
My swap made it about 7K before it found a weak forward drum so I am preparing to rebuild the unit now.
I have the ATSG Update manual for the 4R70W. Does anyone on this site have a pdf of the Factory manual for this transmission? I don't mind buying a manual, however the only thing that I can find is the ATSG manual for the AODE and it may not have the precision measurements that is needed for a professional rebuild of this unit.
Thanks for all the help on this site
#321
04-02-2017, 06:22 PM
Expedition Engine Swap pu
I have a 2003 Expedition that I am going to replace the engine in. Thought about putting in a 5.4 instead of a 4.6 like what was in it. Do the steps you listed mostly relate to an Expedition?
Notes for 4.6 to 5.4 swap Part 1 Revised 04 April 2015
Application: These notes cover the F-150 from 1997 to 2004 Heritage model years. They do not cover swaps to a supercharged 5.4 engine
Before you start: All you are doing is putting a bigger displacement motor in place of your 4.6. I recommend you use your 4.6 ignition and PCM along with its engine harness.
Cylinder Heads: The following info applies to the F-150 and not any other vehicle engine.
4.6 Engine: The 4.6 engine had Non Pi Heads from 1997 to 2000. The Pi heads were introduced to this engine for the 2001 model year.
5.4 Engine: The 5.4 engine had Non Pi Heads from 1997 to 1998. The Pi heads were introduced to this engine for the 1999 model year.
Exhaust: The collectors on the exhaust manifolds are set at different angles and locations. The 4.6 exhaust might not bolt up to 5.4 manifold. You may need to have a muffler shop modify your 4.6 exhaust to match up.
Ignition: All 5.4 engines use Cop ignition. . 2000 and later 4.6 use COP ignition. 1997-99 4.6 engines use coil packs. It is easier to wire your 5.4 using the harness from the 4.6 and use the 4.6 ignition coil packs if applicable. If you use the 4.6 Coil pack ignition you will have to fab a bracket for the driver side coil pack.
Engine harness: To use a 4.6 PCM to run a 5.4 engine: The IAC harness must be relocated to the rear of the throttle body elbow. The oil sender wire on the 4.6 may be too short so measure or test fit the harness to see if it must be extended. All 97-00 and some 2001 4.6 engines use some sort of intake manifold runner control valve. Remove it from the 4.6 and plug it into the 4.6 harness and bolt it to the engine some where out of the way. Note; you can get a tune to remove its function and eliminate it all together.
All 97-98 4.6 engines use an Engine Coolant Temp sensor (ECT) and an Engine Coolant Temp sender. By the 99 Model year the ECT was dropped in both the 4.6 and 5.4 harness as the Cylinder Head Temperature sensor (CHT) was used for the PCM to monitor coolant temps. None of the 00+ 5.4s use ECT sensor or sender. Some of the 99 5.4s still use the sender to feed info to the instrument cluster. You will have to tap the intake manifold crossover pipe to fit the sensor(s) if your 4.6 has them and the 5.4 doesn’t.
Transmissions: the 4.6 and 5.4 have the same bellhousing bolt pattern. That means that all the transmissions will bolt up. All the 5.4 engines have 8 bolt crankshafts. Some 4.6 engines (ROMEO ENGINE) have 6 bolt cranks. You will need the flex plate from the 5.4.
Manual transmissions: If you don’t have an 8 bolt flywheel a flywheel from a 1997-8 4.6 Windsor engine will work. As it has 8 bolts it will bolt right up to the 5.4 crank. Remove the flex plate spacer and install a pilot bearing from a 4.6.
Special note about the different automatic transmissions and their respective harnesses. You cannot run a 4R100 transmission with a PCM that had a 4R70W transmission and vice versa. The transmission harnesses are different and will not plug into the different engine bay harness. The control functions in the PCM are not compatible so the transmission will not function properly.
Torque Converters:
4R70W
ENGINE............Stall Speed............Multiplication
4.2..................1978-2330...............2.3:1
4.6..................2105-2505...............2.3:1
5.4..................1830-2190...............1.9:1
4R100
All Engines......??????....................2.2:1
If you swap a 5.4 into a 4.6 engine bay and use the 4.6 converter you will multiply the 5.4's torque at a higher rate and at a higher stall speed which will put the torque at the transmission input shaft close to the limit if not over the limit of the 4R70W. The 99+ 5.4 produces 350 ft/lbs of torque. 90% of that is available at 2000 rpm. The stall speed of the 4.6 is above the 2000 rpm range so more than 90% is available. 350 ft/lbs x 2.3(4.6 multiplier) x 90% is 724.5 ft/lbs.
Application: These notes cover the F-150 from 1997 to 2004 Heritage model years. They do not cover swaps to a supercharged 5.4 engine
Before you start: All you are doing is putting a bigger displacement motor in place of your 4.6. I recommend you use your 4.6 ignition and PCM along with its engine harness.
Cylinder Heads: The following info applies to the F-150 and not any other vehicle engine.
4.6 Engine: The 4.6 engine had Non Pi Heads from 1997 to 2000. The Pi heads were introduced to this engine for the 2001 model year.
5.4 Engine: The 5.4 engine had Non Pi Heads from 1997 to 1998. The Pi heads were introduced to this engine for the 1999 model year.
Exhaust: The collectors on the exhaust manifolds are set at different angles and locations. The 4.6 exhaust might not bolt up to 5.4 manifold. You may need to have a muffler shop modify your 4.6 exhaust to match up.
Ignition: All 5.4 engines use Cop ignition. . 2000 and later 4.6 use COP ignition. 1997-99 4.6 engines use coil packs. It is easier to wire your 5.4 using the harness from the 4.6 and use the 4.6 ignition coil packs if applicable. If you use the 4.6 Coil pack ignition you will have to fab a bracket for the driver side coil pack.
Engine harness: To use a 4.6 PCM to run a 5.4 engine: The IAC harness must be relocated to the rear of the throttle body elbow. The oil sender wire on the 4.6 may be too short so measure or test fit the harness to see if it must be extended. All 97-00 and some 2001 4.6 engines use some sort of intake manifold runner control valve. Remove it from the 4.6 and plug it into the 4.6 harness and bolt it to the engine some where out of the way. Note; you can get a tune to remove its function and eliminate it all together.
All 97-98 4.6 engines use an Engine Coolant Temp sensor (ECT) and an Engine Coolant Temp sender. By the 99 Model year the ECT was dropped in both the 4.6 and 5.4 harness as the Cylinder Head Temperature sensor (CHT) was used for the PCM to monitor coolant temps. None of the 00+ 5.4s use ECT sensor or sender. Some of the 99 5.4s still use the sender to feed info to the instrument cluster. You will have to tap the intake manifold crossover pipe to fit the sensor(s) if your 4.6 has them and the 5.4 doesn’t.
Transmissions: the 4.6 and 5.4 have the same bellhousing bolt pattern. That means that all the transmissions will bolt up. All the 5.4 engines have 8 bolt crankshafts. Some 4.6 engines (ROMEO ENGINE) have 6 bolt cranks. You will need the flex plate from the 5.4.
Manual transmissions: If you don’t have an 8 bolt flywheel a flywheel from a 1997-8 4.6 Windsor engine will work. As it has 8 bolts it will bolt right up to the 5.4 crank. Remove the flex plate spacer and install a pilot bearing from a 4.6.
Special note about the different automatic transmissions and their respective harnesses. You cannot run a 4R100 transmission with a PCM that had a 4R70W transmission and vice versa. The transmission harnesses are different and will not plug into the different engine bay harness. The control functions in the PCM are not compatible so the transmission will not function properly.
Torque Converters:
4R70W
ENGINE............Stall Speed............Multiplication
4.2..................1978-2330...............2.3:1
4.6..................2105-2505...............2.3:1
5.4..................1830-2190...............1.9:1
4R100
All Engines......??????....................2.2:1
If you swap a 5.4 into a 4.6 engine bay and use the 4.6 converter you will multiply the 5.4's torque at a higher rate and at a higher stall speed which will put the torque at the transmission input shaft close to the limit if not over the limit of the 4R70W. The 99+ 5.4 produces 350 ft/lbs of torque. 90% of that is available at 2000 rpm. The stall speed of the 4.6 is above the 2000 rpm range so more than 90% is available. 350 ft/lbs x 2.3(4.6 multiplier) x 90% is 724.5 ft/lbs.
#323
05-15-2017, 09:42 AM
#324
05-20-2017, 03:46 PM
JMC I wanted to say thanks for all the time and effort you have put into the notes.
I just completed my swap. The truck is a 1999 had a 4.6 now 5.4 only real problem I had were the throttle cable mount the egr sensor mount and had the wrong gasket for the intake
the truck still needs a tune but that will be another day
thanks again
I just completed my swap. The truck is a 1999 had a 4.6 now 5.4 only real problem I had were the throttle cable mount the egr sensor mount and had the wrong gasket for the intake
the truck still needs a tune but that will be another day
thanks again
#325
05-30-2017, 07:29 PM
Notes for 4.6 to 5.4 swap Part 1 Revised 04 April 2015
Application: These notes cover the F-150 from 1997 to 2004 Heritage model years. They do not cover swaps to a supercharged 5.4 engine.
Before you start: All you are doing is putting a bigger displacement motor in place of your 4.6. I recommend you use your 4.6 ignition and PCM along with its engine harness.
Cylinder Heads: The following info applies to the F-150 and not any other vehicle engine.
4.6 Engine: The 4.6 engine had Non Pi Heads from 1997 to 2000. The Pi heads were introduced to this engine for the 2001 model year.
5.4 Engine: The 5.4 engine had Non Pi Heads from 1997 to 1998. The Pi heads were introduced to this engine for the 1999 model year.
Exhaust: The collectors on the exhaust manifolds are set at different angles and locations. The 4.6 exhaust might not bolt up to 5.4 manifold. You may need to have a muffler shop modify your 4.6 exhaust to match up.
Ignition: All 5.4 engines use Cop ignition. . 2000 and later 4.6 use COP ignition. 1997-99 4.6 engines use coil packs. It is easier to wire your 5.4 using the harness from the 4.6 and use the 4.6 ignition coil packs if applicable. If you use the 4.6 Coil pack ignition you will have to fab a bracket for the driver side coil pack.
Engine harness: To use a 4.6 PCM to run a 5.4 engine: The IAC harness must be relocated to the rear of the throttle body elbow. The oil sender wire on the 4.6 may be too short so measure or test fit the harness to see if it must be extended. All 97-00 and some 2001 4.6 engines use some sort of intake manifold runner control valve. Remove it from the 4.6 and plug it into the 4.6 harness and bolt it to the engine some where out of the way. Note; you can get a tune to remove its function and eliminate it all together.
All 97-98 4.6 engines use an Engine Coolant Temp sensor (ECT) and an Engine Coolant Temp sender. By the 99 Model year the ECT was dropped in both the 4.6 and 5.4 harness as the Cylinder Head Temperature sensor (CHT) was used for the PCM to monitor coolant temps. None of the 00+ 5.4s use ECT sensor or sender. Some of the 99 5.4s still use the sender to feed info to the instrument cluster. You will have to tap the intake manifold crossover pipe to fit the sensor(s) if your 4.6 has them and the 5.4 doesn’t.
Transmissions: the 4.6 and 5.4 have the same bellhousing bolt pattern. That means that all the transmissions will bolt up. All the 5.4 engines have 8 bolt crankshafts. Some 4.6 engines (ROMEO ENGINE) have 6 bolt cranks. You will need the flex plate from the 5.4.
Manual transmissions: If you don’t have an 8 bolt flywheel a flywheel from a 1997-8 4.6 Windsor engine will work. As it has 8 bolts it will bolt right up to the 5.4 crank. Remove the flex plate spacer and install a pilot bearing from a 4.6.
Special note about the different automatic transmissions and their respective harnesses. You cannot run a 4R100 transmission with a PCM that had a 4R70W transmission and vice versa. The transmission harnesses are different and will not plug into the different engine bay harness. The control functions in the PCM are not compatible so the transmission will not function properly.
Torque Converters:
4R70W
ENGINE............Stall Speed............Multiplication
4.2..................1978-2330...............2.3:1
4.6..................2105-2505...............2.3:1
5.4..................1830-2190...............1.9:1
4R100
All Engines......??????....................2.2:1
If you swap a 5.4 into a 4.6 engine bay and use the 4.6 converter you will multiply the 5.4's torque at a higher rate and at a higher stall speed which will put the torque at the transmission input shaft close to the limit if not over the limit of the 4R70W. The 99+ 5.4 produces 350 ft/lbs of torque. 90% of that is available at 2000 rpm. The stall speed of the 4.6 is above the 2000 rpm range so more than 90% is available. 350 ft/lbs x 2.3(4.6 multiplier) x 90% is 724.5 ft/lbs.
Application: These notes cover the F-150 from 1997 to 2004 Heritage model years. They do not cover swaps to a supercharged 5.4 engine.
Before you start: All you are doing is putting a bigger displacement motor in place of your 4.6. I recommend you use your 4.6 ignition and PCM along with its engine harness.
Cylinder Heads: The following info applies to the F-150 and not any other vehicle engine.
4.6 Engine: The 4.6 engine had Non Pi Heads from 1997 to 2000. The Pi heads were introduced to this engine for the 2001 model year.
5.4 Engine: The 5.4 engine had Non Pi Heads from 1997 to 1998. The Pi heads were introduced to this engine for the 1999 model year.
Exhaust: The collectors on the exhaust manifolds are set at different angles and locations. The 4.6 exhaust might not bolt up to 5.4 manifold. You may need to have a muffler shop modify your 4.6 exhaust to match up.
Ignition: All 5.4 engines use Cop ignition. . 2000 and later 4.6 use COP ignition. 1997-99 4.6 engines use coil packs. It is easier to wire your 5.4 using the harness from the 4.6 and use the 4.6 ignition coil packs if applicable. If you use the 4.6 Coil pack ignition you will have to fab a bracket for the driver side coil pack.
Engine harness: To use a 4.6 PCM to run a 5.4 engine: The IAC harness must be relocated to the rear of the throttle body elbow. The oil sender wire on the 4.6 may be too short so measure or test fit the harness to see if it must be extended. All 97-00 and some 2001 4.6 engines use some sort of intake manifold runner control valve. Remove it from the 4.6 and plug it into the 4.6 harness and bolt it to the engine some where out of the way. Note; you can get a tune to remove its function and eliminate it all together.
All 97-98 4.6 engines use an Engine Coolant Temp sensor (ECT) and an Engine Coolant Temp sender. By the 99 Model year the ECT was dropped in both the 4.6 and 5.4 harness as the Cylinder Head Temperature sensor (CHT) was used for the PCM to monitor coolant temps. None of the 00+ 5.4s use ECT sensor or sender. Some of the 99 5.4s still use the sender to feed info to the instrument cluster. You will have to tap the intake manifold crossover pipe to fit the sensor(s) if your 4.6 has them and the 5.4 doesn’t.
Transmissions: the 4.6 and 5.4 have the same bellhousing bolt pattern. That means that all the transmissions will bolt up. All the 5.4 engines have 8 bolt crankshafts. Some 4.6 engines (ROMEO ENGINE) have 6 bolt cranks. You will need the flex plate from the 5.4.
Manual transmissions: If you don’t have an 8 bolt flywheel a flywheel from a 1997-8 4.6 Windsor engine will work. As it has 8 bolts it will bolt right up to the 5.4 crank. Remove the flex plate spacer and install a pilot bearing from a 4.6.
Special note about the different automatic transmissions and their respective harnesses. You cannot run a 4R100 transmission with a PCM that had a 4R70W transmission and vice versa. The transmission harnesses are different and will not plug into the different engine bay harness. The control functions in the PCM are not compatible so the transmission will not function properly.
Torque Converters:
4R70W
ENGINE............Stall Speed............Multiplication
4.2..................1978-2330...............2.3:1
4.6..................2105-2505...............2.3:1
5.4..................1830-2190...............1.9:1
4R100
All Engines......??????....................2.2:1
If you swap a 5.4 into a 4.6 engine bay and use the 4.6 converter you will multiply the 5.4's torque at a higher rate and at a higher stall speed which will put the torque at the transmission input shaft close to the limit if not over the limit of the 4R70W. The 99+ 5.4 produces 350 ft/lbs of torque. 90% of that is available at 2000 rpm. The stall speed of the 4.6 is above the 2000 rpm range so more than 90% is available. 350 ft/lbs x 2.3(4.6 multiplier) x 90% is 724.5 ft/lbs.
Last edited by F150250; 05-30-2017 at 07:31 PM. Reason: Forgot to mention the transmission
#326
12-16-2017, 06:46 PM
#327
12-19-2017, 06:20 PM
Junior Member
High idle
Ok so i did the 5.4 swap into my 97 f150 had it swapped and it ran ok had a blown head gasket due to neglet wanting to change it so now i had the heads rebuilt and put back together and it runs good engines sounds good but it idles extremely high at like 2k rpms and when in gear it goes down to 1k or 1500 had iac replaced a few hoses and nothing changed the knock sensor isnt connected im assuming its that but im not sure. Its using the 4.6s wiring and pcm, takes a bit to start also need to give it gas to start it been told it could be a vacumm leak but thats tooken tmcare of and nothing so im hoping its that knock sensor havent driven it in like 2 months now please help any imput is appreaciated. Jonathan
#328
07-06-2018, 07:57 PM
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#329
12-24-2018, 05:21 PM
#330
12-28-2018, 05:23 PM
