HI, just wanted to get some information on these motors. I dont know a whole lot about em', like what makes them modular? What are some of the differences between thh 4.6 and the 5.4? Is it just the stroke and the ignition? Just a couple questions but any info you would like to share would be great. Thanks.
They are modular by the very definition. It breaks down this way:
5.4L is a 4.6L that is stroked, bore is the same as a 4.6L
6.8L is a 5.4L that has 2 more cylinders OR is a stroked 4.6L with 2 more cylinders. 6.8L has the same bore as the 4.6L/5.4L and the same stroke as a 5.4L.
After '00 all modulars have COP ignition, all 5.4L's have COP no matter the year as do all 6.8Ls. There are a ton of little differences between just the 4.6L's check here if you want to know all the little things up to about '99:
There are 2 different modular blocks, the romeo and windsor, for the most part Romeo's are car blocks and windsors are truck blocks but some romeo's are in Trucks as well. In '99 5.4L's got PI heads that increased air flow and changed the piston top, in late '99 early '00 4.6L's got them in the trucks, Mustangs got PI heads/intake in '99 Panthers got it in '01. Fords 2nd or 3rd (depending on how you look at it) generation modulars came out in '04 with the 3V head 5.4L's in the F150's with the 4.6L's to follow. There are of course DOHC 4V 4.6 and 5.4L's, all of which 2V, 3V and 4V use the same blocks, with the exception of the SVT stuff that uses Aluminum blocks in some of their products but the specs are the same.
So in short it is a money saving measure where you cut down on your manufacturing tools when engines share common specifications, it is nothing new almost every engine family does this, this is just the first time it was called what it is, modular AND it was Fords first big move into OHC engines in mass production for trucks and its bigger cars. Being OHC the engines are physically bigger than a 460CI engine even though they are 281 and 331 CI's.
Some basic HP #'s off the top of my head:
First gen 4.6L's 190hp with single exhaust 210 with dual exhaust ('92-'99 or so Panthers)
First Gen 4.6L truck engines NPI 2V 220hp ('97-mid/late'99)
First gen NPI 5.4L's 235hp ('97,'98)
Second gen PI 4.6Ls 230hp
Second gen PI 5.4L's 260hp
Supercharged PI 5.4L 2V 380hp (Lightning)
4V DOHC 5.4L 300hp (Lincoln Navigator)
AL Supercharged DOHC 5.4L 550hp (Ford GT)
Third gen 3V 4.6L 292hp
Third gen 3V 5.4L 305hp
I don't know all the different Mustang hp #'s off the top of my head they range from mid 200's to mid 300's.
There were plans for a 6cyl. modular, a 4.6L minus 2 cylinders, but something didn't work out so Ford developed the 4.2L instead.
I should also note that the 5.4L does not use the same block as a 4.6L, it has too much stroke and is a bit taller, but the heads are the same as well as intake, pistons etc etc.
Last edited by galaxie641; 01-28-2007 at 06:25 PM.