2007 E150 4.6 to 5.4 engine swap possible
 

I have a 2007 E150 can I swap it out for a 5.4L or should I just stick with the 4.6L and build it up a bit... its time for a new motor but I want this one with some kick...

Can't say that I've tried doing that but we have both 4.6 and 5.4l in our fleet that are around that vintage. They are very similar and it seems like the swap would be possible, however I'm sure there would be some extra work involved. If you have a junk yard nearby with the 5.4l that would be better than getting a crate engine since you'd have access to any parts you find out that you need. You'd want the long block with as much included as possible (intake and wiring harness for sure. Accessories probably swap over without a problem) and you probably would need the 5.4L PCM. I don't know if Ford started this in 07, but the instrument cluster is tied to the PCM in our 08. It will not start with an instrument cluster that does not match the PCM.

Stock gearing for the 5.4 is 3.73, your 4.6 is probably 4.10, so you'd have some slightly low gearing but that might not need to be changed. I think the transmissions are identical.

Don't expect to be doing smoke shows and barking the tires between gears with the 5.4L, but if you haul heavier loads it's going to feel a bit more competent.

Del's on the right track here but I'm also not too sure if the 4.6 and 5.4 sensor pack are similar enough those too would be a direct swap.

Were I to attempt this I'd find a similar year donor van and strip out every wiring harness for the engine, instrument cluster and the PCM too.

Ford is semi-notorious for changing minor things between years, one being pin out locations for systems and components that need to talk with one another. I can attest without hesitation the instrument cluster does need to be properly integrated and recognized by the PCM otherwise there will be transmission shifting issues, possibly loss of speedo- or odo-meter function as well.

Like most corporate engines similar years easily swap into almost any chassis, the devil being the details of wiring, sensors etc.