Thread: Explorer 4.0 V6 to 5.0 V8 Swap

Congrats! It really is an awesome feeling when you swap goes great and works like it should. I have stripped the harness down and I will post pics when I come back from Primm. Im going to remove the second o2 sensors since the pcm my friend has is tuned by Juanco and has had all the smog stuff removed. The previous person to try and "strip" the harness just cut out a bunch of stuff but never cleaned it up and left all the pins in the pcm connector in place with wires cut about 6" from the connector. Unpinned all those wires and removed any wire and connectors that they left in the harness that went to nothing or were not needed.

--JosB

Damn site, i forgot that it doesnt like pics that I took with my phone. I already gave the harness back to my friend. Thanks again for those part numbers, friend got those parts in the other day, just need to wait for the short block before we put it together.

--JosB

I've been driving the truck around for the past couple weeks and it has been running great until yesterday. After filling it up with gas the Check Engine light came on. I figured that I just didn't get the gas cap tighted enough but that wasn't it. So I pulled the codes which came up with P0340 which is malfunction for the camshaft position sensor. This morning I pulled the sensoe off and found that the magnet had braken off and bent the synchronizer. So I went to Pick-A-Part and pulled one from another Explorer and installed it on mine. It's now running great again.

I picked up a transfer case today. I'll try to get it installed this weekend and then measure to have the driveshafts done. Hopefully I'll have four wheel drive again soon.

Awesome. Other then that, has it been problem free?

Almost. I had the magnet fall off in the camshaft position sensor and it bent the synchronizer which caused a check engine light. So I went to Pick-A-Part, pulled one and installed it in mine. It's been running great since. The only things I need to fix are the interior lights stay on all the time. So I removed the fuse until I figure out why. Also, the heat doesn't work which I think is the EATC unit but haven't been able to figure it out. Those are the only issues. My brother is going to help me figure out those two.

My brother came over today to help me figure out why the dome light stays on and why the heater doesn't work. Thanks Phil! While he was looking over the schematics I started removing the AWD transfer case. I was only able to remove the driveshaft, exhaust and some of the bolts before he needed a hand with the wiring. He was able to find why the dome light was on and we fixed that wiring. We were still working on the heater issue when it started to get dark so we'll continue on that and I'll continue with the transfer case.

Job well done on the swap!

Saw you the other day in ontario. Lookin good

Thanks.

when are you heading to the ref?

As soon as I have the 1356 transfer case in. I haven't tried to see if it fits yet but from what I have read there are a couple spots on the floorboard that need clearance unless you have a body lift which I don't and don't want. After that I have to fit the linkage and shifter and then have driveshafts made. I'll hopefully be able to work on it again before this weekend but I've been too busy. Once I'm done my brother and I are going to take both of our trucks because he did a V8 conversion on his '78 FJ40 that needs to be BAR certified as well. The good thing about that is the ref we are going to go to was my brothers teacher for a smog class he had to take back when he was the service manager for a Chevy dealer.

That is cool that you guys sort of know the Ref. I was curious because I'm trying to figure out my next move with my swap, and curious as to what they check. Im still trying to figure out if you swap a ranger with a 2.3 to a 4.0, if you even need to see the ref. Thought I remember something about factory option motors. Guess we will find out. ha ha ha.

As long as the 4.0 was an engine option for your year truck then you don't have to have it certified. The only reason I do is because the 5.0 wasn't offered in the 1995 Explorer which is what I have. It wasn't an option until 1996.

ya i have heard that before, but also heard it the other way. So just roll up to a smog shop with a swaped motor and the system will be able to let them smog it?

Yep.

That's cool. I will have to give that a shot. Have u done that before?

fuck tapatalk

Nope, this is my first conversion but that is what my brother told me when I was thinking of doing the conversion on mine. You can always call the smog shop you use and ask. My brother was an ASE master tech and the service manager at Crest Chevrolet before he decided to change careers at 34. He's now a CHP officer.

Ya I ll have to check into that. I ll definately be interested to see how your tip goes. By the looks of it, you wont have a problem.

We had dinner at my brother's house last night so I asked him about it. He confirmed that you just have to take the truck to be smogged like usualy. They can pull up the info for the new engine then and smog it.

Awesome. Thanks for asking him. I ll definitely give that a shot when it comes time.

Actually, he has to have it BAR'ed as it was not a OHV motor. If he had put in the OHV motor, then he wouldnt have to have it barred as it was an engine option. If you look at his sig, the truck is a 96 and the SOHC did not come in that truck as an option. Also, you need the emmisions system of the 02 SOHC on your truck and it can and probably will vary depending on if it came from a Mustang(which you technically cant use since its not a light truck), an Explorer or a Ranger. Cats could have changed from the different models even if they are from the same year, they go of weight and class of vehicle to determine the size cats to use in the vehicle. Always give out all the details of your swap when asking questions, especially what motor you have and what it came out of.

--JosB

Originally Posted by JosB

Actually, he has to have it BAR'ed as it was not a OHV motor. If he had put in the OHV motor, then he wouldnt have to have it barred as it was an engine option. If you look at his sig, the truck is a 96 and the SOHC did not come in that truck as an option. Also, you need the emmisions system of the 02 SOHC on your truck and it can and probably will vary depending on if it came from a Mustang(which you technically cant use since its not a light truck), an Explorer or a Ranger. Cats could have changed from the different models even if they are from the same year, they go of weight and class of vehicle to determine the size cats to use in the vehicle. Always give out all the details of your swap when asking questions, especially what motor you have and what it came out of.

--JosB

I didn't even look to see if he was talking about an OHV or a SOHC, thanks JosB.

I started installing the BW1356 yesterday and found that it is not going to work. It is too wide and won't even clear the frame. So now I'm on the lookout for a manual shift BW4406 that has the speed sensor hole.

Originally Posted by JosB

Actually, he has to have it BAR'ed as it was not a OHV motor. If he had put in the OHV motor, then he wouldnt have to have it barred as it was an engine option. If you look at his sig, the truck is a 96 and the SOHC did not come in that truck as an option. Also, you need the emmisions system of the 02 SOHC on your truck and it can and probably will vary depending on if it came from a Mustang(which you technically cant use since its not a light truck), an Explorer or a Ranger. Cats could have changed from the different models even if they are from the same year, they go of weight and class of vehicle to determine the size cats to use in the vehicle. Always give out all the details of your swap when asking questions, especially what motor you have and what it came out of.

--JosB

Dont want to get too off topic in this thread, but my SOHC runs off an OHV computer, so If the smog guys plug his reader in, reads an OHV, there is a chance I could squeak by. But.... the reason I was asking is because I have a 97 OHV setup sitting in my shed as a last ditch effort. So I was asking on the basis that I put the OHV in. But like I said, If i take it to one of the many "Juan" smog shops, his reader shows OHV, all emissions hooked up, there might be a chance. Thanks for the clarification though. Feel free to look at my thread about my swap and the shortcoming it has. Im definitely open to suggestions and it seems there are only a handful of people who know exactly what they are talking about when it comes to legit motor swaps. Any input is greatly appreciated.

Motor Swap/ Harness/ Smog question (Tried Search)

Originally Posted by 94cobra69ss396

I didn't even look to see if he was talking about an OHV or a SOHC, thanks JosB.

I started installing the BW1356 yesterday and found that it is not going to work. It is too wide and won't even clear the frame. So now I'm on the lookout for a manual shift BW4406 that has the speed sensor hole.

Well that kinda blows. What does your speed sensor read from right now?

The transfer case.

hey 94 cobra69ss396 i hope you keep this goin i joined DR because of your thread im also doin a swap and appreciate the insight

Welcome to DR. I'm still working on it. Right now I'm trying to find a manual BW4406. I found one on Ebay and made an offer so hopefully they take it and I'll have the case soon.

I found a BW4406 on Ebay and ordered it today.

awsome hope to see it soon!

what did ur 4406 come out of ?

1997 f150.

man u guys out in cali do it big my 97 sport is gonna stay 4x4 on 31x10.5 bfg ATs but im goin more towards a sleeper ..should be done with the other junk this weekend and we plan on doin mine next weekend

My transfer case arrived today. I'm meeting carlover over at BTF tonight to take a look at an engine for him so I'll start installing the case tomorrow.

cool cut the tabs off the top and get ur bfh out ..u prob gonna need to clearence the tank bracket i found an awsome thread on serious explorations

I started installing the transfer case today. I went pretty good. I clearanced the body so that the case didn't hit the floor in a couple spots and then bolted it up to the trans. Next up is modifying the front mount for the fuel tank so that it clears the new case. I already pulled it off and cut a section off that wouldn't clear. I also cut a little peice of plate and welded it to the bracket. I still need to shape it and cut some areas of it to clear the tank but it's a start. Below are a few pictures of the bracket.

Another clearance issue I have is the tranmission crossmember because of my SAS. The new case sets the front driveshaft further rearward so the shaft will hit the crossmember. I'm going to have to figure out how I want to redo the crossmember.

The other thing I still need to do is measure to have new driveshafts made. I'll most likely do that before I do the crossmember so that they are being made while I making the crossmember.

I finished up the bracket tonight and reinstalled it along with the tank and skid plate. I'll try to get some pictures of it tomorrow. I also did some trial fitting for the front driveshaft and it looks like I might not have to make a new crossmember. I may only have to modify mine a little more than what I did back when I did the SAS. I won't know for sure until I get the shaft made.

Looking good Ron. I started driving the bronco around town to get some miles on it. Just need to build the single swinger steering this weekend and should be done! I am thinking in May we should plan a weekend and head up to big bear or somewhere you know to do some wheelin.

That's awesome, congrats. How's it ride on the street?

I'm going to measure to have the driveshafts made tomorrow and take my old ones in. Back when I did my SAS my brother had a shop he deals with make the new front one and he's off tomorrow so I'll have him take me to that shop.

If you want to make a day of it like we usually do we can start off by heading up Silverwood then to Dish Pan and if you're still wanting more we'll finish up with John Bull. My brother and I did that a while back when there was snow and we started at 3 in the afternoon. It was dark by the time we got to John Bull but it was a blast doing it at night in the snow.

Driveshafts are being made. They should be ready on Monday.

Here are some pictures of the finished tank support and what I did to the cross member. I dropped the front an inch and the rear 3/4 of an inch. The driveshafts aren't done yet but they said they should be tomorrow.

Tank support.



This is the passenger side but the drivers side was the same way.




This is the drivers side.