HI!... It was offered with the 5.4. The 4R-100 was only offered in some of the 4x4's and the CALIFORNIA emission packages. My father had a 4R70-W in his "97". There was also the spiecal 4R-100 with some desiel internals that was install only in the LIGHTNING.

Well sclime,
My parts guy says there are no pcm's listed for the 5.4 with the 4R70W trans in '98, but if someone that thinks they more than I do can come up with the calibration code off of one of those 5.4 4R70W pcm's, then I can research further. But since I am so uninformed, I am just going to stay out of it and say keep the 4.6 pcm and the coil packs and get a chip burned. Later.......

Thanks SVT for looking into it. I think I will take your advice and stay with my PCM and the coil packs for now. Easier to have a chip burned than trying to change to something that doesn't exist. Since I will have the wiring harness from the new motor, I can always research that as an alternative later. Besides, the flip chip will most likely be cheaper than the new MicroTuner.

Thanks for all the assistance. The motor should be here by Friday.

Steve

Steve,

I will be cheaper to follow svt's advice.
You already have the old engine wire harness and the PCM. Swap them over to the new engine and get a chip burnt for the new motor. You will save the price of a PCM. It should run with the 4.6 PCM but it will not run as well as it could.

JMC

Thanks!!!
I contacted Kar Kraft and the 5.4 is a 2000/2001 so will have the PI heads. I have contacted Mike Troyer and will either have a chip burned or look at the new Micro Tuner. If the motor will run as is, I will at least be able to get back on the road and then add the chip when Mike is back from Florida.

I'm picking up the flywheel today.

Steve

One last thing. Mark every connector from the 4.6 engine so you can match it up to the 5.4 sensors. The 5.4 will not have an Intake Manifold Tuning Valve. They dropped those on the 5.4 sime time in 99.

JMC

The new November issue of Mustand 5.0 has an article where they replace the 4.6 with a 5.4 out of a wrecked E150. The 5.4 Includes dyno testing. I found it informative and learned new thiungs about the 5.4L. For example, the E150 has a lower intake manifold for more clearance.

Pete

Thanks for the updated info. I now have the flywheel and will call Kar Kraft today for a tracking # on the motor. I will make sure to mark the connectors. Good advice.

I think I will pick up a copy of Mustang 5.0 as well as it sounds like that might be helpful.

Thanks JMC and Peter.

The 5.4 from Kar Kraft has arrived. I am picking it up from the trucking company this afternoon. I will update the post once I have a chance to take a look at it. Will begin the swap tomorrow night.

Picked up the motor! :)

It did not come with a wiring harness, but that won't matter as I will switch over to my original coil packs and plugs. Will be contacting Mike Troyer to get a MicroTuner this week and am looking at headers too. Not sure if I want to go with headers or not. Don't think I really need them, but they would be cool.

I will update the post this weekend once I have the new motor ready to go in and let you all know how it goes.

Steve

Just to update where I'm at on this project. The old motor is out as of yesterday. Will begin moving the wiring harness over this week. Looks like there are some differences which I will have to look into.

JMC, You said the 5.4 won't have Intake Manifold Tuning Valve. Do I need to do anything with the connector?

Can anyone tell me where to find an Illustrated Parts Breakout for the 1998 F150 on-line or book?

Thanks,
Steve

Steve,

That is probably the Intake manifold tuning valve. The 5.4 doesn't use one. Have you tried e-bay for a CD or Hays makes manuals for the trucks. What I usually do when I am working an someone else's vehicle is go to the library and look in the reference section for a manual.

JMC

Thanks JMC!

I will check E-bay for a CD. Can also check the local book store for a Hays manual. If all else fails, will check out the library.

Another question....what's the best way to handle the exhaust hook up. I've heard they will be different. I have an Exhaust Pros shop about 10 miles away from me so could tow it there when the new motor is in. Will I need to have a splice welded in?

I also noticed there is a connetor on the back of the 5.4 that doesn't appear to be on the 4.6. Is that something for the other tranny?

Thanks for all your help.

Steve

sclime,

One of the greatest threads on this board! Great info! Hope you all continue to comment in detail. Can hardly wait for the next post! You got the best guys helping you in this thread. Hope you all continue to help sclime with the detailed info. so that,.............I can do my lightning swap! :D

steve,

Help me out here. How many wires and what color? ;)

JMC

JMC!
I will check out the connector tonight when I get home. I'll get the color code for you and update this post.

Thanks,
Steve

Duh!!! It is the oil pressure sensor. I will start working on the wiring harness tonight. Will not get another chance to work on it till this weekend. I will update this post and get some pictures taken this weekend.

JMC, I have one other question. My truck had the remote oil filter. There was a connector on that. Since the 5.4 does not have the remote filter, do I just do nothing with the connector?

Thanks for all the assistance.

Steve

....any updates?:D

You can still use your remote filter. Just unbolt the adapter from your old engine and bolt it to the new one. That will change right over.

Latest update! Got the wiring harness changed over to the new 5.4. Only had to change one connector. The sensor on the top of the block under the intake manifold had a different type of connector. Soldered the connector from the old motor in place. I have the new motor in the truck, but not mated up to the transmission. Ran out of time this weekend. The engine mounts line up correctly so should not be an issue.

Only the right side bracket for the coil packs mount up correctly. There are no bolt holes on the left side. Will need to fabricate a bracket to hold the mount. Also need to pick up two larger bolts for the bracket on the right side of the motor as you face the truck where the power steering resivor connects up. The 5.4 uses a larget bolt.

Will update this later in the week when I have more time to work on it.

Steve

Sclime, I have been following this thread closely as I suspect many others have too. I applaud your pioneering spirit and think that you'll do just fine putting it all together.

I'm not trying to whizz on your parade but I'm just curious to know if you plan on doing some kind of tuning when you have it all togethher and running because of the difference in displacement between the two motors. It's almost a cubic inch difference and will probably run a little on the lean side with the 4.6 PCM and tune. Are you going to a tuner and getting a custom chip burned or maybe going up a size on the fuel injectors? What do you plan on doing to compensate for the increased displacement ?? :thumbsup:

Good question. I have been talking to Mike Troyer at Troyer Performance. He has talked to me about a MicroTuner which he can tune to the 5.4 with the PI heads. I left a message for him last Friday, but will probably call again tomorrow. Will order the Tuner this week and by the time I have it ready to run, should be able to re-program.

Check out this link for pictures.

http://sclime.mystarband.net/




Steve

Update on Superchip. I spoke to Mike Troyer yesterday about the solution to my programming needs for the 5.4. He has new software coming this week which will allow him to custom tune a chip for my situation. Since I will be using the existing PCM and my 4.6 wiring harness with coil packs and plug wires, he will be able to tune to the 5.4. He asked me to get the 4 digit PCM code and will begin looking at the custom tune this weekend. I should be able to have the chip by the end of next week.

I will be working Sat, Sun, and Mon. to complete the installation and get the exhaust work done. I will update this post this weekend. For more info. on the programming, see the thread under Computer Chips (Calling Dr Troyer).

Steve

Great photos ........we need more of them.

Did the engine slide down in the engine bay?
How did you have to modifiy your 4.6 exhaust to fit the 5.4 exhaust manifold connection?

.......I got a million questions, when you finish.

Thanks for providing this thread with detailed updates.

........any updates? :D

In answer to Iron Horse, the engine mounts were slightly tight towards the rear. Had to remove the nuts from the right engine mount bracket and tap it back. Engine then slid in just fine. Transmission bolted up fine. I have not done the exhaust yet. Will be working with the local Exhaust Pros shop to fix that this coming weekend. Had to cut the exhaust just before the muffler to let the cats and Y pipe slide back and down to get the clearance. Will most likely remove the cats and Y pipe to facilitate the exhaust changes. Looks like the header pipes will have to be lengthend and the angle changed to get them to mate up and keep the cats installed.

I had to make a bracket for the coil pack on the right head as there are no mount holes to bolt to. All accessories bolted up correctly. I also retained my remote oil filter. The bolt pattern was the same so easy to do. The serpentine belt is identical so got a new one yesterday and installed just fine. The PCV tubing is different, so have not dealt with that yet. Also have to fabricate a bracket for the throttle and cruise control cable mount as there no bolt holes in the new intake manifold for that. The EGR valve assembly will also require a bracket to be made.

I am working on vacuume hoses and wiring now. Started routing plug wires yesterday and installed the fan clutch assembly. If all goes well, I should be ready to test fire by the weekend. I will take more pictures and post them this week.

Steve

Great info!

........I wonder if a used exhaust system (headers to exhaust tips) from any 5.4 supercab or crewcab, would bolt up without modifications ?

I figured that I will be doing some hacksawing, but, I still need to be able to drive it to the muffler shop. I was hoping that we only needed to cut below the manifold connection area to make the 4.6 exhaust system fit the 5.4.

You may be able to cut just above the cats, but it is tight in there and I was using a sawsall to make the cut. I had thought about getting the exhaust from a wrecked 2001, but have not had time to look into that. I'm guessing I will need to keep the 4 O2 sensors so would like to keep the factory cats and just modify the header pipe. I will try to get some pictures of the exhaust tonight.

Steve

New Pictures Added today.

http://sclime.mystarband.net/

Great. Now after reading this I want to put a 5.4 in MY truck! Thanks alot guys!:D :thumbsup:

Wyhy do you think everyone is following this thread so closely?

I could easily imagine a 5.4 under my hood with all the 4.6 stickers still present where they should be. :devil:

I am running 5.4 headers on my 4.6. The angle of the collector flange ( where header bolts to exhaust system) is different from the 4.6. With the 5.4 deck hight being greater the collector flange sits higher in the engine compartment. You will need to extend the exhaust and bend the flange on the 4.6 exhaust to mate with the 5.4 flange. What I did to make it fit was have a muffler shop make a new exhaust flange from 2½ inch pipe that was about 6 inches long and weld an O2 bung on it. I (temporary) cut out the precats and used 2½ inch flexi-pipe to connect the parts up.

Regards

JMC

I towed my truck to the local Exhaust Pros shop yesterday afternoon to have the exhaust hooked up. Unfortunately, they won't be able to get to it until Monday. I should have an idea of what they did on Monday as well as what it costs. They are going to try to keep the pre-cat in place and just extend the header pipe and add a new flange.

I will post an update when I get the truck back from Exhaust Pros. I will then be able to finish up the wiring and vacuum lines. I was told I should get a code reader and dump the codes before I try to start it, so am checking into renting one from a local parts shop.

Steve

ironhorse...
I checked with a local salvage yard to see if I could pick up an exhaust system from the manifolds to the muffler including the cats and was told they cut them up and cannot re-sell them. I wonder if it is a state or federal law that they cannot re-use the cats from wrecked trucks/cars. I aksed if they could sell just the flange to the cat (minus the cats) and he again said no. They cut them up.

You might check your local salvage yards though. Maybe they operate differently.

I talked to Exhaust Pros yesterday late afternoon. He was just putting my truck on the rack. Will know later today if done.

Also talke to Mike Troyer yesterday about the chip. He is sending me worksheets to complete and will burn the chip later this week.

I do have a question for someone who has a 5.4 2001. On the front of the intake manifold where the crossover is for the return antifreeze is, my old 4.6 had to sensors. The new manifold only has one. I am wondering if I can get away with only the one sensor or am I going to have to wire the second connector into the first one.

Thanks,
Steve

You have to use both. Just go to Home Depot and get a brass T-fitting that is all females, and get an insert the same size. Screw the insert into the manifold, then put on the T, then install both sensors. I'm pretty sure the sensors either operate at diff. parameters, or one is open when hot and the other closed when hot. I'll check schematics later and let you know for sure, but you have to use them both I know that.

The two sensors are for the engine coolant temperature. One sends a signal to the PCM for engine control functions and the other sends a signal to the instrument cluster for the temperature reading on the guage. SVT is right you must use both or at least the one for the PCM. A T fitting is the easiest way.

JMC

EDIT: One should be gray and the other black. The gray sends to PCM and the black to Instrument cluster.

Thanks!
I will make sure they are both hooked up.

I talked to Exhaust Pros and he says he can't do the exhaust as he doesn't have a transmission jack and is not confident he can weld in that tight of space. He recommended I go to a performance shop to have it done. I think I will do what JMC advised and just get two flanges made, one with an O2 lug and then use flexi-pipe to connect up to the cat. I certainly don't have a problem in taking out the pre-cat.

Thanks,
Steve

Update!
I towed my truck to another local shop and they are going to weld up the new flange for me. Should have my truck back by the weekend. Am sending the Superchips worksheets to Mike today so hopefully will have the chip by then too. May actually get to start it this weekend. Will update when I get it back and will get some good pictures of the exhaust hookup.

Go Man Go! .......this is better than any magazine article on the subject! .......trust me, I would know. ;)

I will check on the used exhaust system. I can access a salvage yard that specializes in used Ford truck parts and my state no longer requires any vehicle inspections, therefore no emission testing (thats good and bad).

I have tried repeatedly to download your webpage pics. When you only had three pics. I could download them. Now with several more pics, I can only download one and that takes a while :confused:

....can't wait for your next update! :thumbsup:

come on lets go
 

Lets go already, This is like an automotive soap-opera. Did the 5.4 fire up? Did the exhaust situation get resolved? Did Maria have Carlitos illigitimate child? Oops, got carried away. Sorry.
Mike:banana:

They were working on the exhaust on Friday night. I will talk to them today. Should have the truck back tonight....I hope. I can't wait to get this done. The weather is getting crappy here in Iowa and I need to get my Mustang off the road and into storage. You all will be the first to know when I get it running. All good things come to those who wait. Have patience Grasshopper.

I will update my pictures tonight or tomorrow so you can see what had to be done for the exhaust. I know this has been a slow process. I live in rural America so things take time to get done. Small towns don't hurry on anything.

Thanks for all the encouragement.

Steve

I stopped by last night to talk to the mechanic about the exhaust. He had the cats and Y pipe all off the truck and was in the process of taking out the drive shaft for better access. He still needed to take out the heat shields for access.

He ended up cutting the Y pipe to separate the two cats to make it easier to fit each manifold and will reconnect when the flanges are done.

Today he will have two new flanges made up with the correct bend and will mate them to the pre-cats. He said the Y pipe is stainless steel which cannot be welded so he will clamp it all together. He hopes to have it done by the end of today or first thing on Wednesday.

I will update when I get it back tomorrow.

Steve

I get my truck back today. Stopped last night and the flanges were made and he was getting ready to put in the O2 bungs. We fit it all together and he is welding it this morning.

The new flanges connect from the manifold to the pre-cat and are about 6" long. The bends used were as follows.

Drivers side = 14degree bends
Passenger side = 14degree and a 30+degree bend.

They fit well and will be stock by keeping both the pre-cat and cat in place. The only exception is that I cannot use the original heat shield. Will have to modify the existing one or buy some flexible heat shield material to put in.

I will take pictures tonight and post them so you all can see the exhaust. I should have time to work on wiring and hopefully fire it tomorrow night.

Stay tuned.

Steve

We are ALL staying tuned!!!!!!!!!!

Hope your exhaust shop remembers how to make those 6 inch flanges.......he might get some more business.


:cool:

I have the truck home now and back in my shop. I will take pictures of the exhaust tonight. I will get info on the exhaust shop and post it. I know it was someone local in Perry, Iowa (small town).

Steve
:rocker: