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-   -   4.6 to 5.4 or New heads? (https://www.f150online.com/forums/v8-engines/128794-4-6-5-4-new-heads.html)

sclime 11-17-2003 09:07 AM

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

sclime 11-18-2003 09:53 AM

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

sclime 11-20-2003 12:59 PM

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

iron horse 11-20-2003 01:05 PM

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

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


:cool:

sclime 11-21-2003 09:10 AM

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:

JMC 11-21-2003 09:33 AM

Steve,

I don't need to know about the exhaust. I just want to know if the truck runs? ;)

JMC

sclime 11-22-2003 04:22 PM

:banana:
The moment you all have been waiting for has arrived.

It RUNS!!!!

I finished hooking up the vacuum lines this morning and made a tee fitting for the antifreeze temp sensors. Turned the key and waited about 30 seconds to see if any idiot lights came on. None, so went ahead and cranked it. It sputtered quite a bit, but I floored it and cranked again, this time LIFE. Let it clear a little and it revs and idles just fine.

The only problem I have is where the remote oil assembly connects to the block, needs to have a gasket made as it leaks a little oil. Other than that, I still need to make some brackets for the EGR valve assembly and a stronger bracket for the passenger side coil pack. Have to go to town to get gasket material and a piece of tube for the idle air valve. and should be able to drive it tomorrow.

I still don't have the Superchip, so it is running on the factory PCM and seems to be fine. I'm sure I won't have the power of the 5.4 until I get the chip, but it seems to run fine. Mike has sent the chip in for programming so should have it next week.

I will update the post after I have a chance to drive it.

Thanks for everyones support. Could not have done this without your help. :bows:

Steve

JMC 11-22-2003 08:18 PM

Way to go Steve!!! Good work.

JMC

LE PEW 11-22-2003 09:10 PM

originally posted by Sclime
 

It RUNS!!!!


Congrats!!!!!! I knew it would. Despite all the electronic sensors and sophisticated PCM on the truck it still cant tell if it's all bolted onto a 4.6 or a 5.4 block. You pulled a fast one on the computer. :D

Good job, now I've got a notion to shop around for a lightning short block.

Do you know if Mike Troyer is going to fatten the A/F ratios on your current chip or reprogram it to a 5.4 program from a similarly equipped truck?

Pittsburgh 11-22-2003 11:56 PM

Hmmm after reading this and talking to JMC, think I might have to give this a try.

iron horse 11-23-2003 02:18 AM

Congratulations !!!!!!!!!!!!

......again, thanks for sharing your experience. Look forward to reading your updates. I now feel better about my pending 99' 4.6 swap to a lighting 5.4.
:beers:

sclime 11-25-2003 08:01 AM

LE PEW,
Mike is programming the chip to run as a 2001 5.4. I don't think he is going to fatten the A/F ratios.

I should have the chip by next week. I plan on finishing up the brackets I need to make on Friday this week and will then take it out for a spin. I talked to Ford about the Remote Oil Filter and the O-ring I need, but they don't have one in stock. Will have to make a pattern and check the local auto parts stores for one.

I won't have any time to work on it until Thurs or Fri this week. Will post more later.

Steve

sclime 11-27-2003 10:13 AM

I drove the truck last night. I can tell right away the torque difference even with the PCM being for the 4.6. It seems to run fine, but I know I am not getting the performance out of the 5.4 that should be there. I also did get a check engine light after driving it about 5 miles. Can't speculate what set the light other than the PCM doesn't know how to handle the additional cubes. Should be getting the chip from Troyer next week so will know more then.

Mike told me to make sure and not accelerate too hard with it until I get the chip in so I don't do any harm to the motor. I don't want to set a lean condition and burn the pistons so I will most likely let it sit until I have the chip.

I am getting a slight vibration when I get into high gear under light acceleration and when I let off, it stops. I know I am a little low on transmission fluid, so did not drive it very far. Will add fluid and see if that clears it up.

Any suggestions?

Steve

LE PEW 11-27-2003 01:56 PM

No sense in trying to straighten things out until you chip it. Wait till the you get it from Mike and take it from there. The vibration might be a lean condition. Hang tight and see what the chip does for ya. :thumbsup:

Good luck, keep the updates coming. Happy Thanksgiving to you and your family too!

JMC 11-27-2003 03:20 PM

Steve,

Get the code read to see what is happening. If it is running lean you need to know so you don't melt a piston.

JMC


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