Hello, I have a 2000 5.4 engine from an E350 van. I added a flywheel, clutch and 5-speed transmission from a 4.6 Mustang. I put this assembly into an older truck with the aid of a Detail Zone wire harness and a reprogramed computer.
This set-up starts and runs great and gets good MPG.
The problem is when I wind it up in 1st, 2cnd, or 3rd gear I get a terrific vibration that manifests in the shift stick. I havn't tried to wind it up in 4th or 5th because with the 3.25 Detroit Locker rear gear it goes pretty fast.
I can't seem to figure what is wrong, I have thought maybe the 4.6 and the 5.4 might have different balance values or maybe my clutch cover is out of balance (this is a new take-out Ford part) I bought the clutch assy. From McCloud Clutch Co.
Anyone have any suggestions? Thanks in advance for any help.

 

Well yes I believe you have a balance issue with that many different application parts.
I would say the only way to go is to remove the motor with flywheel/clutch and find a good performance shop that can balance the whole assembly.
It's a lot of work and some expense but if not done you have to live with it.
Good luck.

 

I wouldn't think I would have to remove the engine when I could just as well remove the transmission and flywheel / clutch assy. I can't imagine that the engine would get out of balance without ever being opened up. I was just wondering if the 5.4 and the 4.6 had different balance values? I know some old Chevys had interal and external balanced engines and it was easy to get them mixed up.
The guys at the clutch place indicated that it wasn't their clutch or flywheel that would be out of balance. Said they were balanced during manufacture.

 

You need to do further research on the parts compatability.
As an example, going back to the old 302/5L motors, the balance points were changed between the 302 and 5L versions such that many got into vibration issues by not knowing this ahead of time and getting into incorrect parts compatability just because they happen to bolt up. There are books written on this for just that engine.
For a parts vendor to say his parts are balanced is correct as far as that goes but are they part of the overall balance?
A little imbalance here and there that stack up and you have an issue.
The higher the rpm to worst it gets.
This is why a serious race engine is very finely balanced from the inside out so it can run 9000 rpm without blowing apart from vibration.
Only trying to bring you an expanded view of the overall possible situation you might have.
Let us know how you get it solved.
Good luck.

 

All modulars are internally balanced, so you're not having an issue with some parts being from a 4.6 and others from a 5.4L. Harmonic dampers, flexplates, flywheels, etc are all interchangeable without issues.They're nothing like the differences that the old 5.0L/5.8L had. IMO-you've got a clutch assembly or trans issue that's showing itself.
JL

 

Both Bluegrass and JL have valid points. Were it mine, I'd try some simple stuff first, like pull the drive shaft, rotate it 180 deg., and plug it back in the trans., see if things are the same or +-. If somewhat better or worse, try some worm clamps around the front end of the drive shaft, 180 deg. off set, see if things improve. The shaft might be the problem.

It could also be a bad pilot bearing, or the wrong one. Wouldn't be the first time I've seen this caused by a bad input bearing in the trans.

Was the clutch/flywheel marked for proper orientation when bolted together ?

Dave

 

Another thing is, if the output shaft is in a higher or lower position from the original transmission, the driveshaft angle could give a problem.
This is a more of touchy thing that is often given credit for.
If out of original position and the rear end twists under torque the angle could be the problem.
Rear twist might pull the spline out to far.

 

I have absolutely no idea if this could be an issue, but, it seems to me that, way back when, Ford had some interchange considerations concerning the length of certain tranny input shafts when used with bell housings in a swap situation. If the vibration is THAT bad, the pilot bearing might not even be fully engaged.

I used to change quite a few input shaft bearings in 4 spd. w/od pickup transmissions. The vibration in the shifter felt like every gear was half in/ half out.

Bluegrass may have a point on drive shaft angle. Hard to say without seeing it though. We used to try never to have the angle from the pinion center line to the drive shaft center line, much over 3 deg., it just robbed h.p.. I can't speak to the vibration part though, because with 750-800 h.p., everything tended to vibrate.

Dave

 

Well the way I see it, the driveshaft goes the same speed whether it is in 1 st gear or 5th....I only have found this vibration in 1st and 2nd gear when I wind it up as in drag racing...I'm thinking it might have something to do with the pilot bearing...otherwise the engine runs smooth and quiet. Cruises 80mph with no effort and delivers 21+ mpg.
The noise and vibration seems to eminate from the shifter...
Anyone else care to weigh in on this subject?