I've been entertaining/researching a 12V Cummins diesel swap for my currently 5.4L powered F250 Super Duty, but came across the idea of swapping in a Lightning 5.4L when researching superchargers/turbochargers for the 5.4L. As great as a diesel would be, I do not do much hauling other than my small 16' aluminum skiff and motocross bikes, and I have always had somewhat of an affinity for gasoline engines. I understand that both engines are based on the Ford Modular V8 and share many similarities, but are very different beasts. In doing so, I would be looking for a 2003+ engine due to the better intercooler and improved heads. I understand the mounting is exactly the same, and I could bolt my current 4R100 trans right up to the Lightning powerplant. I've seen a few engines going in the $2500-$3500 range with ~25-35K on them, complete with accessories. It seems this would be much cheaper than the $10K I figured to swap in a Cummins (that includes engine mount kits, gauge adaption, trans. adaptor/flexpate/starter, the actual engine, accessories, and upgrades to make it not so much of a pig).

So to you Lightning owners, and any Super Duty owners who may grace these pages; Is there anything in particular I should look for when researching a donor engine? Is there anything I should know that may negatively affect my decision to move forward with this project? I've most certainly got the skills/tools to do it, the only step now is acquiring parts. I've even got another daily driver I can use during the truck's downtime.

From what I have gathered so far, it seems 2003-2004 is the best model year engines to pursue. Can the engine be plugged directly into my factory 'accessory' harness (gauges, heater, all interior functions/powers)? I understand I will need a full engine harness/computer with the Lightning engine, but that is to be expected.


I know that this is a bit of a read, but any help/tips/things to look and lookout for is greatly appreciated!!

 

I can't help you but I'd really like to hear what responses you get.

Considering no body seems to want to help you, maybe you should post something here.
https://www.ford-trucks.com/forums/forum136/

 

I dunno how I missed this thread.

While it is true the '99/'00 year intercoolers leaked like a sieve, as long as the IC was swapped out by Ford during their customer satisfaction program, they're all the same IC's.

Just FYI, when you say improved heads, if you mean improved flow (for performance) then that's incorrect. If you mean improved heads ala more threads in the spark plug holes (4 thread holes for the '99 - '02 year L's versus 8+ thread holes for the '03/'04 L's), then yeah, that's what you want.

If you have a 4R100 from a PSD, they will not mount to a 5.4L modular. If you have a 4R100 from a 5.4L that's not a Lightning, it will be short lived since the internals are not the same. The L will eat that tranny in short order.

Just the normal stuff I'm sure you're already aware of. Stuff like, what condition was the donor truck in that the engine came from. You know, any flood, fire, or rollover damage, etc. How many miles on the engine. And if possible, what mods were on the engine prior to removal. This will help you figure out how far outside the "safe" parameters the engine may have been run, and possibly how badly beaten on it was.

Before you even decide to go this route, contact Mike at Madenterprise.com. He can give you the low-down on what's in store for you.

Mike has the know-how on swapping the 5.4L Lightning setup into a regular F150, so his help would be invaluable.

http://www.madenterprise.com/scparts.htm

Stewart

 

Cool idea if you can get one for 3k. But why not a supercharger kit for your 5.4 or a V10 or a 7.3 PSD? I'm just curious what these lightning motors have that is so desirable to you?

Stewart_H-Does the V-10 use the same 4r100 as the 5.4?

 

I've never checked into that, so I don't know.

Stewart

 

what year is your Superduty?

do you have the 5.4 3v, or the 5.4 2v?


is it 4x4 or 4x2?


there are lots of little things that will make this swap a horror. especially if you have the 5.4 3v. They aren't compatible with the 5.4 2v setup. Same motor on the bottom end, but the top end and PCM have some significant changes

 

He has either a 02 or a 01 f250 with the 5.4

 

It's an '02 w/ 2V 5.4L. Since doing more research, rather than a complete L engine sway the route I now plan to go is getting in touch with Mike from Mad Enterprises and ordering up one of his 5.4L SC install kits along with a reman stock L Eaton reman charger. The allure is a sleeper Super Duty.

 

Expect this.....

Those are 39.5x15.5 video by commandersander - Photobucket

Mike is the best.....courtesy of Stewart, he helped me a ton in my conversion....

 

Yes please!

However, I'm having trouble emailing him. All the emails I send to mad '@' madenterprises.com get returned to me with the "diagnostic code" stating: 550 relay not permitted.

Another way to get in contact with him?

 

look at old posts from me where stewart and i were talking.....his ph. # is in one of them....

 

Thanks

 

I think I found your problem. It's not Madenterprises, it's Mike at Madenterprise dot com. You added an extra "S".

Here is his address and phone number from his contact page:

MADENTERPRISE
35325 Fircrest Street
Newark, California 94560
Phone: 510/742-6780
Fax: 510/742-6788

Stewart

 

Thanks for the props.

I've met Mike a couple times during dyno day's he's set up, bringing Sal from PSP out to California to tune Lightning trucks.

I've also followed some of Mike's threads on the L forums, detailing his trials and tribulations with his 4V head swap.

Stewart

 

Props given as justified!

I toiled over this swap for waaay too long.....then you stepped in....AND SAVED THE DAY!