96 351w swap into 95 f150
 

I have a 95 f150 351w, I'm getting 20#'s fuel pressure with key on 30#'s at idle and just under 40#'s after removing vacuum line.
is this acceptable fuel pressure? as I have rebuilt and checked all fuel injectors replaced two fuel pressure regulators two fuel pumps
and two fuel filters and it still wants to stall when I give it just a little throttle. when driving I can floor it and it will go faster but it takes forever.
I have replaced map sensor, tbp sensor, iac valve sensor intake manifold temp sensor and any other sensor you can imagine, like o2.
transmission checks out ok. can't find any vacuum leaks. alternator is putting out correct voltage and battery is at over 13 v.
The timing is 10 degrees btdc. Because of the wiring differences between the 96 351w and the 95 and the condition of the egr tubing, I did a complete
egr delete thinking to save money. Can't see how that would cause the stall issue though?The only thing I can think of is maybe an exorcist!
Also had the instrument cluster recalibrated. Any advice is greatly appreciated. Thanks ;-p still smiling just scratching my head!

Yes that fuel pressure is fine.
Did you use the '96 engine wiring harness?

No sir , I kept everything on the 95 f150. The only sensor I had to put in the 96 engine was the air charge temp. sensor.

So you deleted the EGR which means the valve and tube but how did you plug the exhaust and intake?
Did you remove the distributor at any time? If so did you set #1 piston at TDC before reinstalling the dizzy?

96 351w swap into 95 f150
 

I used a plug fitting from a old hydraulic pump to plug the exhaust manifold, and yes I did set #1 piston tdc before stabbing the distributer back in.
it's timed to factory spec's 10degrees BTDC. the engine starts and idles perfectly, it's when I start to give it gas it want's to stall. So I feather the pedal
it recovers and will drive but it wont coast or stop without stalling. When I floor it, it goes, but it acts like I'm dragging a tree behind me.
Is it possible that I need to " chip " it and have it recalibrated or is this truck too old for that?

What did you do to plug the intake where the EGR valve attaches?

96 351w swap into 95 f150
 

I purchased a milled egr plate that bolts to the plenum where the egr valve used to go.

OK lets go back to fuel pressure for a moment. The numbers you posted originally looked good but does it maintain 32-40psi when the engine is under load.. or even when the throttle is goosed with the truck sitting in park? The pressure should never drop below 32psi.. ever, any throttle opening should send it higher.

Just hooked up fuel pressure gauge and key on 20# , running 30# high rpm's still 30#

The stumble on tip in does suggest a vacuum leak though, does this truck have a metal juice can(vacuum resovoir) on the passenger inner fender? Or is that canister plastic? The metal cans always rust out on the bottom where it is mounted to the inner fender. Test that it is holding vacuum by disconnecting the lines right after shutting off the engine, the can should hold vacuum for a period of time so you should hear a little "sip" when the vacuum lines are disconnected.
What is that all about, you had the cluster recalibrated for what?

Ok, the 96 had a plastic canister and the 95 had a soup can. it was removed with the egr system.
https://cimg6.ibsrv.net/gimg/www.for...e8dea9daa9.jpg

Ok you went a step too far with that, the HVAC controls will also do funky things without a vacuum resovoir. Is the white line that goes into the cab through the firewall near the blower motor connected straight to manifold vacuum now?

What motor was in this truck before the 5.8 swap?