Ok, here's my situation. Friend of a friend had a 5.4L E250 with a bad motor. He also had a good 4.6. SO, he decided to pay "Billy Bob" to put the 4.6 in the van. He even took it to an exhaust shop and had them cobble ithe exhaust to make the 4.6 manifold fit up to 5.4's y-pipe. Well, it actually runs. Problem is though that it has a knock. I'm thinking perhaps because he used the 5.4's ignition system that it could be a spark knock? Also I was browsing through the threads and found a lot on 4.6 to 5.4 swaps and JMC had mentioned that the 4.6s had an intake runner? If this is so I wonder how he got that to work....I know that he used the 5.4 Controller and harness, so I was hoping someone may have some input. I was thinking of going to a junkyard getting a harness, controller, and dual coil pack ignition system... I havent plotted the data yet to see if its running rich/lean or what codes it has, but I'll get that this weekend and update this thread.

 

If you use the 5.4 engine harness all you need to do is wire the 4.6 up like it was a 5.4. You eliminate any sensors that the 4.6 has that the 5.4 doesn't need. Ask Billy Bob which torque converter he used? The knbock could simply be from the 4.6. How sound was the 4.6 engine in the first place?

JMC