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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
#361
Thank you!
the other was a ford expedition eddie bauer 1997 with a running 5.4 engine
Without knowing i assumed they both shared somewhat swappable parts lol
so i decided to swap the 5.4 in the f150 ..the guy that did the swap for me quit on me half way done it was running but very rough ...i decided to learn more and finished the job myself ....its been 4 years and truck is running strong
My question is would it be better to run the transmission from the expedition or just leave the one from the 4.6 1998 f150...i did have to rebuild the 4.6 after installing the 5.4 engine seems to me it put alot of power on the 4.6 transmission and eventually gave out
so should i just swap the trans mission for the 5.4 it is bigger in size ..iwas told i would have to adapt the transmission mounts
ALSO WHAT CAN I DO TO INCREASE TORQUE AND ADD A 4X4 feature?
#362
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#363
Tell me about it !
I had to figure that out the hard way ....still to this day i have been trying to figure out what came from the expedition and what stayed from the f150 .....i think the transmission is starting to give out again so i might just put the one that it needs or a 4x4 conversion ......i dont mind dumping money in too this truck ,i hate car payments so im sticking with my TREX (F150).
#364
Get your 4R70W properly rebuilt, in 1999 they replaced the E4OD with a 4R70W in most 5.4 trucks so it can easily handle yours. I recommend BCA.
https://www.bcawebstore.com
Note that a 4x4 conversion would require a different transmission, the tailshaft is completely different.
If you want more power out of your 5.4, do a PI head conversion. 99 and later 5.4's in F150's were PI.
https://www.bcawebstore.com
Note that a 4x4 conversion would require a different transmission, the tailshaft is completely different.
If you want more power out of your 5.4, do a PI head conversion. 99 and later 5.4's in F150's were PI.
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#365
I need help! 4.6 2002 to 2000 5.4
I have a 2002 f150 that used to have the 4.6. I swapped a 5.4 2v out a 2000 f150 in it and I can’t get it to start it just turns over. I think the 4.6 had 2 knock sensors and the 5.4 has one? And the sensor on the bottom of the air manifold I just plugged it in and left it hidden under the new manifold that doesn’t have a sensor on it. Should that be alright?
#366
Which spark plugs do I use
Notes for 4.6 to 5.4 swap Part 2 Revised 04 April 2015
PCM and Tuning: it should start and run using the 4.6 PCM so if it doesn't there is something wrong with the wiring or a sensor. That is assuming t hat the 5.4 engine is mechanically sound. It is best to have a custom tune done to accommodate the extra displacement of the 5.4 when using the 4.6 PCM. You should be able to use the 4.6 MAF as any competent tuner can adjust for it. It is always best to discuss this with your tuner.
Knock Sensor: The 97-98 99 4.6 uses a 2 wire knock sensor. The 97-98 5.4 has 3 wires of which one is a ground for the shield. Both have a Yellow /red wire to pin 57 on PCM.
1997-98-99-2000-01 Yellow/red to 57 on PCM 4.6 Same for 5.4.
97-98 Pin 91 feeds power for 4.6 and other components. Same for 5.4
1999- 2000-01 Pin 32 for power. Same for 5.4
2002+ Cannot confirm.
Accessories: Some engines have 8 rib serpentine belts and some have 6. Be sure to check so that your accessories have the correct pulley. The original alternator, Air Conditioning compressor, water pump and power steering pump can be reused by changing the pulleys. You also can cheap out and use a 6 rib belt on an 8 rib pulley.
PATS (Passive Anti-Theft System) : The 1999 model year saw the introduction of the PATS as standard equipment on the F-150. If you try to use the PCM from a PATS equipped truck (1999 +) on a non PATS equipped truck (1997-98) you will run into wiring problems. The instrument cluster in PATS equipped vehicles communicates with the PCM and they share security data. The work as a pair and if you use a different PCM they will need to be reprogrammed to work together. For a PATS capable PCM to function in a Non PATS vehicle the PATS function in the PCM must be disabled. So a 1999+ 5.4 PCM in a 1997-98 truck will need to have its PATS disabled. 1999+ 5.4 PCM in a 1999+ 4.6 Truck will need to have the PCM configured to the 4.6 instrument cluster or have the PATS disabled.
Misc: Both engines use the same engine mounts and their location on the block are also the same so your old ones will fit. Unbolt and place aside the AC and PS. You need to remove the intake manifold for the engine to come out. Yes there are 3 bolts on the starter.
PCM and Tuning: it should start and run using the 4.6 PCM so if it doesn't there is something wrong with the wiring or a sensor. That is assuming t hat the 5.4 engine is mechanically sound. It is best to have a custom tune done to accommodate the extra displacement of the 5.4 when using the 4.6 PCM. You should be able to use the 4.6 MAF as any competent tuner can adjust for it. It is always best to discuss this with your tuner.
Knock Sensor: The 97-98 99 4.6 uses a 2 wire knock sensor. The 97-98 5.4 has 3 wires of which one is a ground for the shield. Both have a Yellow /red wire to pin 57 on PCM.
1997-98-99-2000-01 Yellow/red to 57 on PCM 4.6 Same for 5.4.
97-98 Pin 91 feeds power for 4.6 and other components. Same for 5.4
1999- 2000-01 Pin 32 for power. Same for 5.4
2002+ Cannot confirm.
Accessories: Some engines have 8 rib serpentine belts and some have 6. Be sure to check so that your accessories have the correct pulley. The original alternator, Air Conditioning compressor, water pump and power steering pump can be reused by changing the pulleys. You also can cheap out and use a 6 rib belt on an 8 rib pulley.
PATS (Passive Anti-Theft System) : The 1999 model year saw the introduction of the PATS as standard equipment on the F-150. If you try to use the PCM from a PATS equipped truck (1999 +) on a non PATS equipped truck (1997-98) you will run into wiring problems. The instrument cluster in PATS equipped vehicles communicates with the PCM and they share security data. The work as a pair and if you use a different PCM they will need to be reprogrammed to work together. For a PATS capable PCM to function in a Non PATS vehicle the PATS function in the PCM must be disabled. So a 1999+ 5.4 PCM in a 1997-98 truck will need to have its PATS disabled. 1999+ 5.4 PCM in a 1999+ 4.6 Truck will need to have the PCM configured to the 4.6 instrument cluster or have the PATS disabled.
Misc: Both engines use the same engine mounts and their location on the block are also the same so your old ones will fit. Unbolt and place aside the AC and PS. You need to remove the intake manifold for the engine to come out. Yes there are 3 bolts on the starter.
swapped the 5.4 into my 4.6 engine bay. Which plugs do I use? The 4.6 plugs? Or the 5.4?
#367
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#368
#370
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.
so basically the 4.6 to 5.4 swap is swapping long blocks, will my shorty headers fit the 5.4 if im using the cats/y pipe off the 5.4 truck
#371
2001 4.6 to 5.4 Trick Flow head swap.
I recently done this swap..I built a 5.4 using Trick Flow heads and MHS Custom grind cams ..Compression is 10.1 with longtube headers. 2600 Stall..Factory 3.55 gears..Custom tuned. It feels as week as the 4.6. Doses not even feel like I changed the engine. Really feels like the timing is retarded but even with the 4.6 it always felt like I was pulling a trailer behind it especially in the summer.
#372
Notes for 4.6 to 5.4 swap Part 1 Revised 04 April 2015
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.
.
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.
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Am I not able to use the CHT as one the of temp sensors? Maybe for the PCM monitoring.