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1987 - 1996 F150 & Larger F-Series Trucks 1987 - 1996 Ford F-150, F-250, F-350 and larger pickups - including the 1997 heavy-duty F250/F350+ trucks

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  #1  
Old 09-17-2014, 11:49 PM
'90-f150-302-5spd '90-f150-302-5spd is offline
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Almost done with 351W swap, need advice

Hey,

I've been working on a 5.0L to 5.8L and Mazda 5 speed to ZF 5 speed swap for the past few months. I got the engine and trans out of a 1989 F-250 and they're going into a 1990 f-150.
After a longer than expected wait and price sheet from the machine shop I finally got the engine back for the full build-up and have it just about buttoned up.
I have a few questions to ask ya'll.

My wiring harness from the 5.0L Is in rough shape and the 5.8L was cut off when the engine was pulled. I went to the salvage yard and found the only good harnesses were the ones with the newer large 1-piece square connector to the body while my truck has the older style with the 4-separate connectors. Is there any way to re-pin or solder the old style onto the new harness (so long as the donor harness is not MAF)?

Also, the new throttle body has both of the connection points for the EVAP system (one between both intakes on outboard side and the two on the inboard side that connect via Y). Does it really matter which one I use as long as I plug the other?

Finally, I am eliminating the smog pump but I am keeping the EGR system. I have a set of Hedman full length headers on their way from summit. They do not have the EGR attachment bung welded on them. Would it be advisable to just find where the EGR tube hangs down onto the header from the valve and just weld the appropriate pipe coming off of it?

On the ZF 5-speed, is it possible to just go ahead and replace the input and output shaft seals before getting it in just to find out the seals leak? Or does that involve disassembling the transmission?

Thank You for any insight you may have.

Here's whats going in.

Click the image to open in full size.
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  #2  
Old 09-18-2014, 09:13 AM
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Conanski Conanski is offline
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Quote:
Originally Posted by '90-f150-302-5spd View Post
Is there any way to re-pin or solder the old style onto the new harness (so long as the donor harness is not MAF)?
Yes, but you will have to trace and label all wires in both harnesses to know where to put them, wiring diagrams may not be a lot of help.

Quote:
Originally Posted by '90-f150-302-5spd View Post
Also, the new throttle body has both of the connection points for the EVAP system (one between both intakes on outboard side and the two on the inboard side that connect via Y). Does it really matter which one I use as long as I plug the other?
No

Quote:
Originally Posted by '90-f150-302-5spd View Post
Would it be advisable to just find where the EGR tube hangs down onto the header from the valve and just weld the appropriate pipe coming off of it?
Yes, and the female end of another EGR tube works great as the weld on fitting.

Quote:
Originally Posted by '90-f150-302-5spd View Post
On the ZF 5-speed, is it possible to just go ahead and replace the input and output shaft seals before getting it in just to find out the seals leak? Or does that involve disassembling the transmission?
That is a good idea but I don't know what is involved in doing it.
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1990 5.0HO AOD XLT X-Cab F150 3.55LS, 1994 3.0L 5-sp x-cab Ranger 3.45, 2004 3.0L 5-sp X-cab Ranger Edge 4.10, 2004 2.5L 5-spd Subaru Legacy
1996 Kawasaki ZX11D, 2004 Honda 599, 2008 Kawasaki KLR650
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Old 09-18-2014, 05:53 PM
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Subing to this, I have plans to do a swap like this myself and wanna see your end results, I'm hoping to get it done by no later than the end of this year if I can help it.
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Old 09-18-2014, 10:44 PM
'90-f150-302-5spd '90-f150-302-5spd is offline
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Thanks for the insight Conaski. I'll probably steer away from the harness re-pin. I gotta do some looking around about the ZF seals.

I also threw in the Crane CompuCam 444232. Do you know what distributor gear type is recommended? I cant figure out what the cam is made from and I know that different cam materials require different dizzy gear materials for proper wear.

Thanks again
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Old 10-01-2014, 06:30 PM
'90-f150-302-5spd '90-f150-302-5spd is offline
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Well, I got the 5.8 and zf dropped in today. My next step is to start looking at exhaust setups. I also got the bung welded up on the headers for the egr. That idea to use another egr tube worked great.

If going with duals, is 2.25" from collectors back alright? Or if going with a single, what size do you recommend from collectors to Y, then from Y back?

Thinking of using dynomax super turbo or dynomax VT muffler(s). Any recommendations on a quite muffler with good tone? No cats by the way.


Thank you
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Old 10-01-2014, 07:14 PM
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Quote:
Originally Posted by '90-f150-302-5spd View Post
I also threw in the Crane CompuCam 444232. Do you know what distributor gear type is recommended?
That flat tappet cam needs a cast iron distributor gear, be sure to follow the breakin procedure to the letter and always add a ZDDP additive at every oil change.
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Paul (Conan) O'Brien

1990 5.0HO AOD XLT X-Cab F150 3.55LS, 1994 3.0L 5-sp x-cab Ranger 3.45, 2004 3.0L 5-sp X-cab Ranger Edge 4.10, 2004 2.5L 5-spd Subaru Legacy
1996 Kawasaki ZX11D, 2004 Honda 599, 2008 Kawasaki KLR650
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Old 10-02-2014, 12:42 AM
'90-f150-302-5spd '90-f150-302-5spd is offline
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Thanks for the reply, I forgot to mention i figured that out.

As far as the exhaust goes, I would like to go with a single setup, but I've found a couple "header-back dual exhaust" setups. But they're 2.25" dia. I know that there's a good chance they wont just line up with the headers, but they oughta get them close enough that it'll be much easier to modify that system than build a custom Y-pipe from scratch.

As far as performance goes, the 5.8l got the cam, heddman long tubes and a K&N-style custom filter setup. I plan to use this truck as a truck and not something I expect to try and race every guy that pulls up next to me at a light. So if it loses power on the top end, but has some good low torque, I'll be happy.

Thanks again
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Old 10-02-2014, 12:42 AM
 
 
 
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