5.4 engine swap
Senior Member
Joined: Jan 2005
Posts: 266
Likes: 0
From: NewYork
Hi, Jim
I actually have an aluminum 5.4 intake which I did some mods to. Take a look,
http://i527.photobucket.com/albums/c...d/DSCF0044.jpg
http://i527.photobucket.com/albums/c...d/DSCF0045.jpg
I ported out the upper aluminum manifolds divider, did some minor porting to it and did HOURS or diegrinder work on the exterior of it. There is so much mold flash and extra bosses on it, I spent a long time cleaning it down, expecially between the runners.
Where the elbow goes on, you can see an adapter, I made it to use a Lightning plenum and throttlebody, which I did have on my truck and running. The skinny threaded rod was used as a plenum support. You can simply use a stock elbow on it again, but one of the two bosses to bolt down the throttle cable linkage plate are gone, when I cleaned it up. No corrosion, and it will come with the lower manifold, and custom adapter.
If you want it since you bought the motor from me, just pay for it's shipping. If anyone else wants it, I do want some $ for it.
Lowflyingbird
http://i527.photobucket.com/albums/c...d/DSCF0044.jpg
http://i527.photobucket.com/albums/c...d/DSCF0045.jpg
I ported out the upper aluminum manifolds divider, did some minor porting to it and did HOURS or diegrinder work on the exterior of it. There is so much mold flash and extra bosses on it, I spent a long time cleaning it down, expecially between the runners.
Where the elbow goes on, you can see an adapter, I made it to use a Lightning plenum and throttlebody, which I did have on my truck and running. The skinny threaded rod was used as a plenum support. You can simply use a stock elbow on it again, but one of the two bosses to bolt down the throttle cable linkage plate are gone, when I cleaned it up. No corrosion, and it will come with the lower manifold, and custom adapter.
If you want it since you bought the motor from me, just pay for it's shipping. If anyone else wants it, I do want some $ for it.
Lowflyingbird
Technical Article Contributor
Joined: Dec 1997
Posts: 9,417
Likes: 11
From: Windsor,Ontario,Canada
Just so you know if you use the 4.6 intake and an adapter the EGR tube running up from the exhaust manifold will not line up / fit. If you use 4.6 manifolds and the plastic intake manifold the EGR tube will not line up. Some creative bending and it could be made to fit. 
If you have the cash I would recommend getting headers as the manifolds and all will line up properly.
Regards
Jean Marc Chartier
If you have the cash I would recommend getting headers as the manifolds and all will line up properly.Regards
Jean Marc Chartier
Thread Starter
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Member
Joined: May 2008
Posts: 17
Likes: 0
JMC and Lowflyingbird - the responses are all very helpful. JMC I have been reading all your post about the swap, but must keep in mind I still need to pass smog check here in CA. I had been leaning towards headers - do you have a favorite brand/model you would recommend? Keith, I will send you another email separately. Jim
Technical Article Contributor
Joined: Dec 1997
Posts: 9,417
Likes: 11
From: Windsor,Ontario,Canada
Gibson, Bassani, JBA. Are expensive but of good quality. I want long tubes so I have been looking at OBX on e-bay. I had a set of Headman's on the 4.6. and am currently running JBA's with the 5.4.
Regards
Jean Marc Chartier
Regards
Jean Marc Chartier
