Engine Motor swap from a 2003 Explorer

[1996mustang new]

Hey everyone,

Just joined the forums. Looking forward to contributing as I accumulate knowledge.

I'm working on a 1996 Mustang for a Lemon race. It has the stock 4.6L motor which unfortunately has a busted timing cover and a bad head gasket. I opted to just swap the motor as I found it to be a potentially cheaper and more fun option after talking to machine shops about prices. Also, the new motor is a lighter aluminum block and it is a PI motor so I get more HP.

I picked up a 4.6L 2V SOHC from a 2003 Ford Explorer. The motor is solid but in doing the swap I have a few questions.

First, here is what I've done thus far.

1\ Swapped the fuel rail to the new intake. The old fuel rail did have a return line. I simply removed the fuel injectors, swapped the rails, and re-installed fuel injectors.

2\ Swapped the exhaust manifolds. The explorer exhaust manifold has the EGR pipe connection on the passenger side, not the driver side. I realized after that the EGR pipe still doesn't fit so I cut off middle section of it and used a rubber house so I had more flexibility.

3\ Put on the mustang motor mounts.


How does the above sound so far?

Now for the questions:

1\ I've read I gotta swap oil pans and oil pickup tube as well. Is that right? Not a big deal if so but don't wanna do it if not needed. My garage already has enough oil on the floor.

2\ The coolant return line and oil filter housing (its a single piece) is shaped differently. The explorer piece will interfere with my steering pump assembly. I swapped the pieces. Looking at the underside of the pieces they are nearly identical but I noticed the oil supply and return holes were marginally bigger on one piece than the other. I think this is OK but wanted someone to confirm I can do this.

3\ Since my old timing cover is busted I do not plan on swapping it since it would cost me 200 bucks to get a new one. It looks like the only real issue is that the Explorer timing cover does not have the necessary holes for the ignition pack backets which come on the older mustang. I'm confident I can fabricate something here. So my plan is just to us the serpentine belt and pulley setup from the explorer motor.

4\ The mustang intake has 2 ports for water temp. The explorer intake has 1. Any ideas here?

And here is a pick of the car, prior to taking out engine. If you zoom in you can just see the roll cage.

All the best,
Adam

 

[Noobz347]

4\ The mustang intake has 2 ports for water temp. The explorer intake has 1. Any ideas here?

I recently discovered from another thread that the single port is for the temp sensor that feeds the ECU while the other is for the gauge.

Your intake is missing the port for the gauge and you'll need to rig something up.

Also: The two sensors are not the same. The one for the ECU functions like a switch while the other acts more like a variable resistor (it scales). They are not cross compatible.


Good luck with your project.

 

[1996mustang new]

@Noobz347 That is very helpful. I would like a gauge sensor here. I think I'll drill and tap the PI intake so I can thread in the sensor.

 

[1996mustang new]

Hmm, there is actually already a fairly large hose barb in that location. I'll have to see what that does before I go messing with stuff.

 

[Noobz347]

Yeah, I would try and find a proven solution before drilling any holes.

I have not come across anybody's 'fix' for this scenario, yet. It's not to say that one does not exist.

 

[squeak93]

I've done this swap, twice. Drill and tap the metal crossover, IIRC there is a flat spot on it that will allow you to tap for the second sensor. The rear of the explorer intake does not have the provision for the heater core hose so you'll have to rig something up. It's been about 15 years so I'm working off of a tired, old memory but I ran a hose up to somewhere on the front, maybe to the water pump.

You will want the timing cover so your accessories work, oil pan and pick up tube OR make sure if you use the exploder front stuff that you have the correct water pump/pulley combo. It's likely the other version of what the 96 had (long or short, can't remember which had which). Go ahead and change the front and rear seal while the motor is out and accessible.

 

[1996mustang new]

Thanks @squeak93

My plan has been to stick with the explorer timing cover since my mustang timing cover is broken. It already has a water pump on there and I am gonna get an AC delete pulley since we dont use AC. The only issue is potentially the steering pump as its still attached in the car. I have no idea if it'll fit the 03 explorer timing cover. Any idea?

If not, I'll be forced to get a 1996 timing cover that is in good order and swap things over which would be unfortunate but do-able.

Adam

 

[squeak93]

AC and Power steering should bolt right up. Might have to experiment on belt size but you should be good to go otherwise.