Hello,
Hoping some wise members here can help me confirm what my options are to replace a seized engine in my 2011 E-350 with 5.4L Flex Fuel engine.
I'm wondering if I can open my search up wider than the standard recommended 09-16 Flex Fuel van engines that salvage yards are listing. Is it possible to use an older 2v 5.4 engine and just swap my intake manifold, injectors, and other accessories over to it? If so, what other years and models can I look at (trucks included)? Having trouble confirming that for sure, hoping someone here can help clarify for me.
Located in the Denver area and hoping to find an affordable engine ASAP!

*Salvage yards list the following as direct replacements:
FORD E-150 2009 - 2014
FORD E-250 2009 - 2014
FORD E-350 2009 - 2016
Ford E-350 Wagon 2009 - 2016
Ford E350 Wagon 2009 - 2016
Ford Econoline 2009 - 2014

Thank you thank you,
Bryan

 

The vans only ever got the 2v motor so any 2v motor should be a candidate but Ford updated the heads around '06 to combat the spark plug issues so you may want to use that as the cutoff.

 

Beginning about 2000 the E-Series did get the PI heads so that's a major consideration as well.

For the most part if a scrap yard engine doesn't already have an ejected spark plug chances are good it won't experience that with further use. Of course how and who installed the existing set of plugs could affect that. I'd renew the spark plugs using the proper installation procedure before placing the engine in the frame. I'd also use Ford's stainless steel exhaust studs and nuts to eliminate that as an issue in the future.

 

Thanks guys, appreciate the responses!

Sounds like there might be some other options — could you break it down for me into what specific years, makes, and models would be compatible? Any less or more desirable than others? Any specific things to check for to qualify or disqualify a replacement motor?

Really appreciate it — I am ready and willing to do the work but just trying to define what I need.

 

If the Flex Fuel option included parts particular to it and it would affect the engine block and heads then you would be limited to that as a search. IF the Flex Fuel option is mostly in the intake then your idea buying an engine older than your particular year would be possible.

I'm not familiar with the Flex Fuel option in how it affects the induction system, if no one else here chimes in with something definitive and/or hands-on with such a transplant maybe post this in the FTE sub-forum for V8 Modular Motors. Some of those replies might be about the F-Series but they might speak to how or if the Flex Fuel thing affects a non-Flex Fuel long block transplant.

Sorry I can't be more helpful------good luck with your search and install!

 

I spent $3K on a new engine from Fraser earlier this year. The Labor was another $1K but the 5 year warranty on the engine gave me peace of my since I expect to have the van for another 5-7 years or longer.

 

Hello, to follow up I found that any 5.4 2v SHOULD work… just needs to be stripped down to the bare longblock and have all parts swapped over from my original engine.

I identified that trucks and SUVs up to 2003 should have the 2v (Wikipedia was actually very helpful with this confirmation). I believe around 2000 they switched to the PI head which is preferred but either version should be compatible.

I searched local salvage yards for 2001-2003 F150, F250, Expedition, and Excursion. Many had the 4.6 but about 1/3 had the 5.4. I found a good swap candidate from a 2003 Expedition with 168k miles (sticker on window) which cost $275 and I actually had someone at the yard pull it for me for $100… it took him under an hour!

Got the motor home and did a leakdown test which looked good, and now I have the engine on a stand and have stripped it down, cleaned it up, and gone over everything.

Broken exhaust manifold studs were a pain but eventually got them out and replaced with new.

I just installed the upgraded cast iron tensioners, and the guides and chain looked good. Resealing everything as I go. Had to swap valve covers and oil pickup tube and oil pan.

The only other part from the Expedition I plan to use is the intake manifold because my original was full of chunks of piston and valve and I didn’t feel I could clean it out properly. From what I can tell the manifolds are the same. I will use my original fuel system and DBW throttle body of course.
Important: remove the cast coolant crossover pipe, remove the seals, clean the area and inspect the plastic lip on the manifold where the seal sits both top and bottom. Very common failure spot which leads to coolant leaks. I have seen 2 manifolds with this crack but was able to find one in good shape for $30 at the yard.

I cleaned the crap out of my original oil pan and reused it. I replaced the oil cooler with a new Dorman unit. My exhaust manifolds were so rusty and Dorman replacements were so cheap I ordered new manifolds as well.

I’ve got about $400 into the motor and $300 into parts / gaskets… could have spent less bit it was a good time for a refresh.

I hope to complete motor prep today/tomorrow and then think about putting the motor back in the van… hopefully it goes reasonably smoothly!

Side note: not installing the oil cooler until after the engine is back in. It’s location so low and behind the subframe makes it really vulnerable when R&R the engine. Also have to wait to install the intake manifold until the motor is in, of course.

 

Did the swap work? I’m looking into doing this myself soon.

 

The biggest unexpected snag that I remember from this is to make sure to check your crank and cam gears for the correct number of pickup points!
I checked the crank but I didn't check the cam and as it turned out, the number of pickup points on the cam gear for the cam sensor in the new engine was different than in the original. This led to a check engine light when I started the engine and I immediately knew what it probably was.
Because the cam and cam gear are one piece, I had to actually swap the entire cam / cam gear combo. It would have been easy on an engine stand, but I had to do it after I had installed the engine into the van and that was definitely more of a pain in the ***... but I did it, and it fixed the problem.
I think that was the only snag... the rest went as planned and worked out fine. I only put a couple hundred miles on the van after the swap but I confirmed no issues were jumping out. I sold the van, but the new owner was really happy about it and then I did see it on the road about a year later so lets hope the new owner has had a great experience with it.

 

Thank you so much, I have a 2011 econoline as well and found a 2002 expedition as a donor. I can now go into this project with more confidence, thanks!

 

Sure, hope it helps. I just went through one step at a time -- so much easier to do while its on a stand and already apart so just take your time with it. I definitely recommend a leak down test on the new motor as the first thing you do as well. Also, the exhaust manifold bolts are prone to breaking so start soaking them as soon as you can and proceed carefully with removing them if they need to be replaced. If/when they break, it goes downhill fast.
Best of luck!

 

Just make sure to use your intake manifold, fuel rail and injectors
The flex fuel is the pump, fuel sensor and the injectors mainly and the programming to match
Base engine is the same, flex or no flex

 

so you put a 2 valve into a 2011 what did you do about the computer did you switch that or any wires and also did the 2011 transmission fit on it i have a 2003 5.4l expedition with all good running gear and computer but my 2011 5.4l is no good i was thinking about swaping it thank you