I need to replace the 5.4 Triton in my 1997 4X4 Expedition, and I would like to upgrade while I am at it, if possible. I have access to the following upgrade engines: (1) 2002 2V 5.4 Expedition; (2) 2003 2V Expedition; (3) 2002 4V Navigator; (4) 2003 4V Navigator; (5) 2004 3V F-100. All engines come complete with exhaust manifolds, injectors, coils, and wiring to the firewall – some do not have accessories; a/c compressor, power steering pump, alternator. Would any of these choices provide a “plug-n-play” swap? Will any pose more challenges than others? Would I be better off going for a newer vehicle – maybe a high mileage 2003? Thanks for any and all advice and technical information!

 

#2 would be the closest. It has PI heads and will require the matching intake manifold, but the exhaust should be the same.

 

Thanks for te helpful info. The engines all come with intake -- they appear to be composite rather than metal. Has anyone out there attempted an '99 - '02 Navigator 5.4 swap into a '97 - '02 Expedition? Does anyone know if the 4V heads have the same external dimensions/geometry as the 2V heads?

 

There is a gentleman on the other F-150 forum that has done this swap. Send me an email, and I'll try to point you in the right direction.

Personally, I'd swap in the motor that LXMan suggested, and slap this baby in.

The guy that swapped the 4v Navi motor in did have quite a bit of trouble, to me, this would be the way I'd go.

 

The 4V heads are twice as wide as the 2V heads so it will take more modifycations. The 2V engine will have more low end torque for pulling than the 4V engine, too.

 

Superrangerman, I don't have email privileges yet. I'll send the email when I have such privileges in hand. Thanks for the info and advice.

Lxman and Superrangerman, I like low end torque, and so, I'll probably go with the 2002 2V, unless . . . .

I see a low-mile salvage 2001 Lightning F-150 is now available. The engine and trans appear not to have been involved in the damage. Putting aside reliability issues for the moment, does anyone know how difficult it would be to put the 2001 Lightning engine/trans into a 1997 4X4 Expedition?

 

Err... I see I missed typed what I really meant to say...

I meant to type that I'd go with the 2v and a blower, and not a 4V.

 

You will need the complete wiring harness and fuel pump assembly along with the lines if they are larger from the Lightning. They Lightning uses the 4R100 tranny and a 10.25" rearend to hold up to the added power. Make sure that you get the Lightning PCM, and MAF too. Personally, I would get the 2V engine and an aftermarket Supercharger if you want more power.

 

Thanks for the advice. I have decided this vehicle is not worth turning into a high dollar street rod, and so, I ordered the 2002 2V engine and new shocks.

 

Good deal, let us know how it runs when you're done.

 

Alright. I have secured from eBay a 2000 model year 5.4L Triton engine. It was being used in an engineering laboratory on a dyno to test propane injectors to be used on a large fleet of trucks, and so, I have no idea precisely which truck engine it resembles. It is a complete engine with exhaust, intake, the L-shaped alloy pipe that bolts to the intake, coil packs, injection rails, and the original stock gasoline injectors. It has just over 34 hours of run time (nearly all under 2000 rpm), and it has been sealed and stored for the past four years. All cold leak down testing parameters are normal for a new engine. It has no wiring harness or ecu.

The engine will be delivered early next week, and now that I have the project in front of me, I am concerned that the end result might not be able to pass state (California) smog testing. It cannot pass the tests if any engine related light is on.

Plan A is to swap the engines, and the '97 transmission, induction devices, exhaust manifolds, accessories and sensors on the new '00 engine. My points of concern in doing this are as follows:

1. I have assumed without checking that the transmission bolts without modifiation or an adapter.

2. I am hoping the '97 ecu and relevant sensors are compatible with the PI heads and '00 intake manifold. By compatible, I mean able to work together sufficiently well to pass emissions testing. I originally did not think this would be a problem because these forums are littered with reports of replacing the '97 and '98 heads with PI heads. However, I spent some time reviewing these threads, and I could find none that discussed the emissions issue. I am having visions of having to drill and tap holes in the composite intake manifold -- or worse yet -- having to secure a new harness, ecu, and whatever other numerous things may be attached to and/or integrated with the ecu -- like possibly the dash panel gauge cluster for starters. But no, . . . Ford couldn't have made it this hard, . . . could they?

3. I am hoping the accessories and stock exhaust manifolds bolt up without modifications -- are the exhuast ports bigger on the PI heads -- I may be spending time in a junk yard looking for exhaust parts -- or maybe I should break down and get some aftermarket headers -- does anyone have an opinion about who puts the most science into headers these days?

4. Finally, even before I get to any of the foregoing issues, I am wondering whether this engine comes out and goes back in from the top or bottom. Even though this is a 4x4, it looks to me that it might be just as easy to drop everything out the bottom, assuming it is even possible, rather than removing the entire front end and pulling the engine forward and up. Does anyone have any ideas on this issue? I see the labor manual shows this to be a 22 hour job.

As I proceed with any helpful information you can provide, I will report on all problems encountered and the solutions. I am now grateful that you all persuaded me to give up the idea of putting a Lightning engine in this thing. However, if this turns out well, maybe that will be my next project. I have also a 2001 Expedition that begs to become a project.