4.6 liter rebuild question
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4.6 liter rebuild question
Hello all. Im new here and I have a quick question. I used the search but didnt find what I needed so I prolly did it wrong.
Anyway my question is:
Is there something about the 4.6liters that make them not worth a rebuild? Mine has almost 180000 miles on it and is doing ok right now but I am trying to plan a little for the future. Im keeping the truck, 1997 XLT 4x4 ext cab,. If the tranny goes i figure im just going to find one in a junk yard because I have never known a tranny rebuild to last a long time. Engine wise, I was going to do the whole thing, new pistons, rework the heads etc. I figure its a lot cheaper than a new truck, but i wonder if its worth it or if I should just try to hunt down on with low mileage in a junkyard. Thanks for any suggestions.
Anyway my question is:Is there something about the 4.6liters that make them not worth a rebuild? Mine has almost 180000 miles on it and is doing ok right now but I am trying to plan a little for the future. Im keeping the truck, 1997 XLT 4x4 ext cab,. If the tranny goes i figure im just going to find one in a junk yard because I have never known a tranny rebuild to last a long time. Engine wise, I was going to do the whole thing, new pistons, rework the heads etc. I figure its a lot cheaper than a new truck, but i wonder if its worth it or if I should just try to hunt down on with low mileage in a junkyard. Thanks for any suggestions.
Technical Article Contributor
Joined: Oct 2005
Posts: 25,641
Likes: 19
From: MI
It's very hard to find a worthy re-builder for these modulars. The top notch suppliers/builders have been known to screw up the rebuild on these.
I would definitely buy used from salvage. There still tested and warranteed enough so that your protected against internal problems resulting from doner impact.
Good thinking on the trans as well - same for the motor
These guys find a used unit for you in your area by typing in your zip - they start close to home and work there way out when searching.
http://car-part.com/
I would definitely buy used from salvage. There still tested and warranteed enough so that your protected against internal problems resulting from doner impact.
Good thinking on the trans as well - same for the motor
These guys find a used unit for you in your area by typing in your zip - they start close to home and work there way out when searching.
http://car-part.com/
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Thanks for the info. It seems to be in line with the info I have been finding and I dont think getting a tranny and engine from the salvage yard will be hard since it seems like the same 4.6 and tranny are still being used or at least were up untill the early 2003, or 04. Forgive the ignorance but what exactly is a modular motor? I have rebuilt a couple of old 318's in the past but it was for my father in law. Ive always been a ford man but i have never done much work on them other than regular maintanace items.
Technical Article Contributor
Joined: Oct 2005
Posts: 25,641
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From: MI
No problem - Modular is the Family type - Tritons & Intech's (lincoln's) - Started with the 4six in the early 90's. Ford could retool to build any Modular in very short period of time.
What's so special about that??
They did it all at the same plant
Something like that , look it up for long version ... ( :
What's so special about that??
They did it all at the same plant
Something like that , look it up for long version ... ( :
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thank you for the info. I had just stumbled across it after a google search and your info is 100% in line with the other I found. There are a lot of good folks here on this forum. Very knowledgable. With my new work hours im gonna have to pay someone to do all the work
because im just not going to have enough time. I 'll just have one pulled from the yard i suppose but im hoping to avoid that for another year or two. Im figureing on doing the engine and tranny together so it will be which ever goes first. I love that ol' truck and im just gonna have to give it a transplant rather than get a new one. 
because im just not going to have enough time. I 'll just have one pulled from the yard i suppose but im hoping to avoid that for another year or two. Im figureing on doing the engine and tranny together so it will be which ever goes first. I love that ol' truck and im just gonna have to give it a transplant rather than get a new one.
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Joined: Jan 2005
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From: Fort Worth,Tx
its not to difficult overall the small blocks are about the same to rebuild as a push rod. just the cam doesnt run through the valley. but ur best bet is just buy a new one the 4.6 is a dime a dozen
Senior Member
Joined: Sep 2003
Posts: 6,760
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From: Nebraska
Id just pick up a 4.6 or 5.4 out of a junk yard too...
Throw a 5four in and it will be a whole 'nother truck
Throw a 5four in and it will be a whole 'nother truck
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Senior Member
Joined: Jun 2005
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From: Bryant, AL
Originally Posted by Bartak1
Id just pick up a 4.6 or 5.4 out of a junk yard too...
Throw a 5four in and it will be a whole 'nother truck
Throw a 5four in and it will be a whole 'nother truck
Senior Member
Joined: Sep 2003
Posts: 6,760
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From: Nebraska
Here are a few notes from JMC. I was thinking he did a write up about the whole thing though...
Your blower wont fit on a 5.4 though. The 5.4 has a wider deck than the 4.6. Im not sure if they make any type of adapters or not that would allow your blower to bolt up
Originally Posted by JMC
Here is the most recent info that I have on the subject.
Notes for 4.6 to 5.4 swap
Exhaust: The collectors on the exhaust manifolds are set at different angles and locations. The 4.6 exhaust will not bolt up to 5.4 manifold.
Ignition: All 5.4 engines use Cop ignition. 97-99 4.6 engines use coil packs. It is easier to wire your 5.4 using the harness from the 4.6 and the 4.6 ignition coil packs. If you use the 4.6 Coil pack ignition you will have to fab a bracket for the driver side coil pack.
Engine harness: The IAC harness must be relocated to the rear of the throttle body elbow. The oil sender wire on the 4.6 is too short so it must be extended. All 97-00 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. Some use 2. None of the 99+ 5.4s use any. You will have to tap the intake manifold crossover pipe to fit the sensor. Some 4.6 engines (97-8) have two sensors.
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.
Tuning: It is best to have a custom tune done to accommodate the extra displacement of the 5.4.
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.
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.
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. 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 fore 5.4
2002+ Cannot confirm.
JMC
From another post of his
A 2002 4.6 to 5.4 swap is the easiest to do. Pull the old engine and install the new engine. Use the vacuum lines and IAC and PCV lines from the 5.4 but the wire harness from the 4.6 as you are sure that it works. Lengthen the IAC wires so they reach to the rear of the throttle body elbow and lengthen the oil pressure sending unit wire. You will still need to have a muffler shop adjust the exhaust to make it fit on t he 5.4 collectors.
JMC
Notes for 4.6 to 5.4 swap
Exhaust: The collectors on the exhaust manifolds are set at different angles and locations. The 4.6 exhaust will not bolt up to 5.4 manifold.
Ignition: All 5.4 engines use Cop ignition. 97-99 4.6 engines use coil packs. It is easier to wire your 5.4 using the harness from the 4.6 and the 4.6 ignition coil packs. If you use the 4.6 Coil pack ignition you will have to fab a bracket for the driver side coil pack.
Engine harness: The IAC harness must be relocated to the rear of the throttle body elbow. The oil sender wire on the 4.6 is too short so it must be extended. All 97-00 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. Some use 2. None of the 99+ 5.4s use any. You will have to tap the intake manifold crossover pipe to fit the sensor. Some 4.6 engines (97-8) have two sensors.
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.
Tuning: It is best to have a custom tune done to accommodate the extra displacement of the 5.4.
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.
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.
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. 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 fore 5.4
2002+ Cannot confirm.
JMC
From another post of his
A 2002 4.6 to 5.4 swap is the easiest to do. Pull the old engine and install the new engine. Use the vacuum lines and IAC and PCV lines from the 5.4 but the wire harness from the 4.6 as you are sure that it works. Lengthen the IAC wires so they reach to the rear of the throttle body elbow and lengthen the oil pressure sending unit wire. You will still need to have a muffler shop adjust the exhaust to make it fit on t he 5.4 collectors.
JMC
Senior Member
Joined: Jan 2005
Posts: 5,389
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From: Fort Worth,Tx
if ur going for performance. do a .03 bore on the 4.6 and get a forged rotating assembly the 4.6 is proven to make more HP than the 5.4 that is the reason the new GTR doesnt use the 5.4 it uses a bored 4.6 that makes 480hp compared to the 380 that the 5.4 twin cam made.
Senior Member
Joined: Jun 2005
Posts: 603
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From: Bryant, AL
Originally Posted by Faster150
if ur going for performance. do a .03 bore on the 4.6 and get a forged rotating assembly the 4.6 is proven to make more HP than the 5.4 that is the reason the new GTR doesnt use the 5.4 it uses a bored 4.6 that makes 480hp compared to the 380 that the 5.4 twin cam made.
This way my charger will mount the same way with NO changes. I would most definately go with a forged bottom end since I wouldn't mind pushing 14-15lbs.How about the tranny....will a monster box be the route to take or something else?
My truck has the 8.8 rear-end but I think it will be OK.
CDB