So....... I've spent a lot of time calling junkyards and emailing websites for used 02'-03' 5.4L engines. They are all telling me that those newer engines will not work in a 98' F150. I called tree Ford dealerships and they said the same thing, not compatible, electronics or bolt on accessories bosses. They will not interchange. The auto recyclers use Hollander for their interchangeability info. I found out that Ford has their engines remanufactured at AER in Carrolton, TX. They're supposed to do extraordinary work. What do you guys have to say? Now my head is spinning. I don't want to end up with an engine that starts spiting out codes because it wasn't designed to work with the 98' cpu, emissions, or what ever else could be different.

 

You're in over your head, and need to just pay someone to do it. NEVER trust those monkeys at the salvage yard-they know nothing more than what the screen tells them. I myself WILL NOT purchase ANY "mass remanufactured" engine. I've never once had a good experience with one-they always have some sort of problem, so a long time ago I made it a policy to never use them, and have been much better off since.
JL

 

Is it safe to buy remaned engines off Ebay? I see some are significantly cheaper than one that would come from ford?

Also, I am also highly interested in a 02-03 5.4L for my 1998 truck... pass on any info if possible.

 

I'm not in over my head, I deal with these type of technical issues often. I just want some rock solid info from some people that have done these swaps. Are there any block bosses that have been moved that will affect the installation of my 98' 5.4 accessories to the newer 02' to 03' blocks or not? Will the wiring harness from my 98' work on the 03' engine, I heard the temp sensors are now split and located in different areas of the engine so some sort of adaptation has to be done there. Also heard larger injectors had to be used with the swap to the PI heads? Not to disregard any of the valuable info from the posters that helped me in the column above, but is there a shop in the USA or a poster on this site that specializes in these type of swaps that I could call to answer all these interchangeability questions. I've read about so many of these swaps being done but there's always conflicting info that makes it difficult to get a rock solid indisputable procedure for doing a swap between these model years. I would love to see/read a documented procedure on how exactly to do it, every single item. What fits perfectly, what needs slight modification, and full electronic compatibility issues and answers.

I wonder if I could just have my block rebuilt and acquire some rebuilt 02' to 03' PI heads and intake and assemble it that way. Are the cats an issue, would I have to change them. I already have a set of JBA shorty headers and a Flexolite E-fan to install. Those three mods along with my Edge Evo. should get me up near 300 hp which would be fine for my needs.

By the way, I really do appreciate all the help offered from each and every one of you so far!!!

 

Well i did the complete swap for my truck by myself in my shop. I have about as much first hand knowlege as anyone about the situation.

A reman engine is only as good as the mechanic that builds it. Also know that the quality control will not be there like it is when a ford technician builds an engine.

Best bet is still buying a used motor somewhere.

Electronics will all 100% be compatiable. No need for injector changes or anything. Anybody that tells you different doesnt have a clue what hes talking about.

The only changes from a 98 Engine to a 02-03 enigine mechanically. are.

Better flowing heads
Better cam
Flipped the dish of head/piston (still has same comrpession though)
I think maybe a better flowing intake (not sure)

This all nets you 35 hp and 15 ftlbs of tq.

Your stock computer will make that up no problem. It would be a direct swap.

 

That gives me a little more confidence BURNS.....

Definitely a better flowing port matched intake, I've seen pics of the two side by side. I also heard the intakes although changed, staying aluminum from 99'- 00' then went to plastic composite. I would tend to stick with aluminum intakes for a better seal.

And no flash is needed at the dealership for the newer engine, my cpu will relearn the AF ratios and work fine, right. The new JBA shorty headers I bought for the 98' (yet to be installed) will bolt up the same to?

I've also read many threads on other Ford truck sites and many of them say the spark plug threads only increased count in the 03'-04' model years. Before this I heard it was from 99' - 03'. what's your stance on that. It seems, no one knows for sure. I sure won't get an engine (especially order one from abroad only to find out it has the thinner SP casting with less thread in it. I also heard it was a change from 3 threads to 5, and more recently from 5 to 8 threads from the NPI to the PI engines.

Ordering a used engine from a distant salvage yard seems so risky, especially paying freight and some have core charges also. I was told by a local junkyard that finding an 03' 5.4L with low miles given its 2011 will be extremely tough. I saw some online that were from 50K to 80K at prices ranging from $1300.00 - $1800.00. The reman. shops I've talked to want a core back that is the same year as the one I'd order. I've dealt with junkyards for decades and would have a hard time believing I would be getting a great shape low milage engine. Many of them said they run them, do leak down tests, and clean them. Reading reviews of same, many said they got engines with low oil pressure or bad head gaskets or worse. Do you see my quandary. I don't expect anyone to do my research for me, just solid experienced advice. By the way, are you a ford technician?

One more question: If needed to bring it into a Ford dealer in the future for some really technical problem should I tell them about the swap and if so would they still work on it?

Thanks again for the help, I do very much appreciate it!

 

They wont be able to tell if you swapped it or not. Unless they are looking for a specific problem with the engine. Say cam issue.

I wouldnt buy anything from a junkyard that is distance. Buying from junkyards are a risk you take.

My particular engine had 135k on it when i found it sitting under a hood of what was left of a truck. It had been there for 2 years. I swapped it in and it has been there for 4 years or so now. truck now has 220k on it, 155k when i swapped it. And the truck gets beat on very very hard. I tow a 7500lb trailer that is far to heavy, and i drive with a heavy foot anyways. Truck uses about a quart of oil ever 4k miles. Some times smokes a bit at startup (valve guides most likley). But still runs stronger than any stock 5.4l i have driven.

So its a risk buying a used motor.

NO FLASH REQUIRED!!!

 

So I can swap my 1998 5.4L for a 2003 5.4L with no flash?? WOW! seriously?

 

You can.
But it will run better and more powerful with a tune for the 03 - 5.4

 

It would run even better with custom tuning.

 

What do you do then, remove the cpu and bring it to the dealer for the 03' flash or send it via mail to some company that does it for you?

What did you pay $ for that 03' smoker BURNS....? I'll have my eye out for an 03' low mile engine and snap one up that tests out good. I called 2 Ford dealers today and they want $4500.00 for a 03' long block plus $1500.00 for the core. They will not accept any other year engine returned as the core other than the year your ordered it for. So $6500.00 for a long block + tax. I could buy a whole used truck for that...lol and I would still have to find an 03' intake to boot?

 

Wow,
for $6500. you could buy a built block ,ported heads,performance cams.
Then you could spend a little more and put a lightning intake assembly on it...lol

On the tuning.
For a good custom tune you just buy a hand held tuner, have someone put a custom tune on it. Plug it into your truck and load the tune in your trucks computer yourself.

 

So once I get the 03' 5.4L engine I could have Gryphon put a custom tune in my Edge Evolution and use that. Then when I went to the dealership for tough tech issues, if needed, I could then just load the factory program back into 98's pcm and that would settle this hole thing??? lol............

I wonder if the the O2 sensors would be affected or need to be changed to the 03' applicable ones to avoid incompatibility codes from popping up?

 

Yes.
I don't know anything about your make tuner ,but if you can have a custom tune put on it. You are correct. That's all you need to do.

The 02s are the same.

 

First off my engine is not a smoker.

Secondly It was in perfect shape when i bought it 4 years ago with almost 100k less miles on it. I gave $300 i believe for it.

Bill at PHP (Gryphon) can set you up. He did for me. I had an edge evolution, and he traded me a gryphon and put custom tunes on it so my 4.6l ecm could run my 5.4l.

The truck ran for a year with the 4.6l stock ecm on the 5.4l with out one code or issue.



Your truck will run just fine without any tuning at all. NO CODES!! as long as you install everything correctly. If you want more power buy a hand held tunner and put the truck on a dyno.