Hello all,
I own a 1997 Expedition Eddie Bauer 4x4 5.5L. I have loved this truck and it's given me very little problems (save the coils ). However, the truck has 317,000 miles on it with original everything and I know something is going to fail soon (knock on wood). Here's my dilemma: the 5.4 is a good engine but non-rebuildable. You can get a new motor from Ford but there aren't many options for power upgrades. What I would love to do is put a trusty 5.0L Windsor motor in it once my motor finally fails. Carbureted, super simple setup. However, I have heard that this is a lengthy and arduous swap.
Here's where I might reveal my inexperience 😂. I haven't ever done any swaps before, just rebuilds, so correct me if I'm wrong.
I believe the main problem will be getting into my borg-warner 4406 T-Case. I have an E4OD trans, and I know that many 90s Ford transmissions are similar. Since AOD and E4OD were put on the same 90s F-Series trucks with 5.0L, wouldn't they be about the same? Could I put an AOD transmission in and therefore make everything fit with a 5.0L? Will an AOD transmission hook up to my Borg-Warner T-Case? I'd love to do this swap, but I need some help

Thanks everyone,
Henry

 

It seems to me with all you have to do you should find a 5.0 4X4 and use the engine, trans, and transfer case from the same truck. That way you know it will all work together. I assume there is no emissions testing where you live. The major issue I see is getting your non computer controlled power train to integrate with your computer controlled truck.

 

Ok thanks for reply. Would it also be possible to use my current E4OD transmission? Is there a standalone controller for it?

 

The trans bolt pattern is different between the modular motor and the Windsor motor.
I am curious as to why you say the 5.4 is not rebuildable.

 

Ok, thanks, that was one of my questions 2trux.

The reason I say the 5.4l is non rebuildable is that my local machine shop told me everything in that motor is throw away: pistons, heads, crank, most parts of the motor. He said for the money I might as well just buy a new/reman motor from Ford for about the same price of rebuilding and get the warranty that comes with it.
My machinist may be BSing me but it seems to me that he would rather get a job rebuilding my motor than spend time spouting lies to me
Anyway, if I swapped bell housing could I possibly make it work?

Thanks for the help,
Henry

 

Swap E4OD's. Get one from behind a 4wd 5.0/5.8/4.9 engined truck and it will bolt right up, bolt right in, and bolt right up to the transfer case too. E4OD's don't have separate bellhousings.
Considering the size of the engines, you will have room to spare under the hood, I'd move up to a 5.8/351W myself. How to make it actually work in there, I have no idea. Surely somebody out there has swapped in a Windsor into one of these or a truck, which would be close enough. Find them and see how difficult it is/was. (Or that it's not possible?)
Going carbureted means you will need a a controller for the E4OD. Baumann sells a kit that runs close to $1000 that will make it work. I don't know of a cheaper option.

 

A 5.4 long block runs you about 2400 bucks with a 450 dollar core charge from Rockauto, I am sure this is a lot less of a headache and probably not that more expensive to put in, than to try to shoehorn a 351W in there. Is it worth it? Probably not, you could buy a newer Expedition for that I'm sure. But if you want to keep this one on the road, that would be the route I'd take.. Putting a 351W in there with a carb means that a lot of the electronics won't know what's going on, and the instrument cluster won't work. Might be able to hack something to work, or build a new cluster, but it's not gonna be cheap or easy.