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- Joined
- May 8, 2014
- Messages
- 13
- Reaction score
- 0
- Points
- 1
- Vehicle Year
- 1999
- Make / Model
- Ford
- Transmission
- Manual
1999 ranger 3.0 to 5.0 swap
the first thing i did was pull the engine and trans from the donor truck which
was a 1998 expo.
then i pulled the steering column and instrument panel. followed
by the brake peddle assembly. and shifter cable and throttle cable. pretty straight
forward process. I also pulled the whole exhaust system from the explorer.
i pulled the fuel lines and rest of the wiring i thought i would need.
after going through the 5.0 and replacing common wear items such as water pump and timing chain.
i also replaced all gaskets and seals then the oil pump.
the next step was to strip the ranger the same as the expo.
once engine and trans and exhaust were removed i
pulled the steering column and brake peddle and clutch peddle assm. and instrument panel throttle
cable and slave cylinder were also removed.
then i compared both trucks to note differences. a few that jumped out at me were the power steering
coolers were different and would have to be swapped.
the tach wire that i read about was confusing because
of what i was seeing in the trucks them selves. so after looking at the wiring diagrams on alldata i chose to take the wire from C214 slot 16 out of the expo and put it in the ranger to ground. as both trucks
had the black and yellow wire in pin 8 on connector c216.
The clutch interrupt had to be modified to allow the truck to start with only the neutral safety switch on the
transmission. i did this by cutting the pink and white wire and joining it to the one next to it.
I chose to order a fuel rail and injectors from a 1999 expo and also an ecm and wiring harness from a 2000 expo.
this required me to have the PATS system reprogrammed at the dealer for 48.00
Once the insides were swapped i swapped the power steering coolers, and then modified the small sub wiring harness
that goes to the starter. all i took from the expo were the positive batt cable and starter solenoid wire and swapped
them with the ones that were in the ranger.
the next task was to set the 5.0 in place.
first thing i ran into was the drivers engine mount bracket was not going
to fit the ranger frame mount. i solved this by removing the engine bracket and slotting it. i could have changed frame
mount but did not wish to remove the front axle assembly to do it. after that modification it was a straight forward
install. next issue i ran into was the output flange on the expo transfer case would not bolt to the ranger drive shaft
i solved this by taking the front drive shaft flange off the expo shaft and placing it on the ranger shaft.
swapping the wiring harness from a 2000 expo and all the sensors from the 98 donor i had to replace the upstream o2
sensor drivers side and the oil pressure sensor so they matched the new harness.
once wiring was complete i filled with
oil and coolant and test fired. i had to use the entire pats system with ecm from the 98 to get it running and to the
dealer to reprogram for the electronics i would use in the end.
the exhaust system is mostly that from the expo but the muffler is moved back to the factory location for the ranger
and a new tail pipe. last thing to do will be swapping out the cup holder with one from an automatic.
I will update with pictures as soon as i sort them and put them in order.
Price list
donor 800.00
gaskets and exhaust manifolds - 300.00
plug wires coolant fluids and plugs and others from oreillys - 460.00
fuel rail w/injectors -75.00
ecm- 39.00
cam shaft sync- 36.00
wiring harness -150.00
O2 sensor - 33.00
reprogram -48.00
exhaust work -275
total-2216.00
the first thing i did was pull the engine and trans from the donor truck which
was a 1998 expo.
then i pulled the steering column and instrument panel. followed
by the brake peddle assembly. and shifter cable and throttle cable. pretty straight
forward process. I also pulled the whole exhaust system from the explorer.
i pulled the fuel lines and rest of the wiring i thought i would need.
after going through the 5.0 and replacing common wear items such as water pump and timing chain.
i also replaced all gaskets and seals then the oil pump.
the next step was to strip the ranger the same as the expo.
once engine and trans and exhaust were removed i
pulled the steering column and brake peddle and clutch peddle assm. and instrument panel throttle
cable and slave cylinder were also removed.
then i compared both trucks to note differences. a few that jumped out at me were the power steering
coolers were different and would have to be swapped.
the tach wire that i read about was confusing because
of what i was seeing in the trucks them selves. so after looking at the wiring diagrams on alldata i chose to take the wire from C214 slot 16 out of the expo and put it in the ranger to ground. as both trucks
had the black and yellow wire in pin 8 on connector c216.
The clutch interrupt had to be modified to allow the truck to start with only the neutral safety switch on the
transmission. i did this by cutting the pink and white wire and joining it to the one next to it.
I chose to order a fuel rail and injectors from a 1999 expo and also an ecm and wiring harness from a 2000 expo.
this required me to have the PATS system reprogrammed at the dealer for 48.00
Once the insides were swapped i swapped the power steering coolers, and then modified the small sub wiring harness
that goes to the starter. all i took from the expo were the positive batt cable and starter solenoid wire and swapped
them with the ones that were in the ranger.
the next task was to set the 5.0 in place.
first thing i ran into was the drivers engine mount bracket was not going
to fit the ranger frame mount. i solved this by removing the engine bracket and slotting it. i could have changed frame
mount but did not wish to remove the front axle assembly to do it. after that modification it was a straight forward
install. next issue i ran into was the output flange on the expo transfer case would not bolt to the ranger drive shaft
i solved this by taking the front drive shaft flange off the expo shaft and placing it on the ranger shaft.
swapping the wiring harness from a 2000 expo and all the sensors from the 98 donor i had to replace the upstream o2
sensor drivers side and the oil pressure sensor so they matched the new harness.
once wiring was complete i filled with
oil and coolant and test fired. i had to use the entire pats system with ecm from the 98 to get it running and to the
dealer to reprogram for the electronics i would use in the end.
the exhaust system is mostly that from the expo but the muffler is moved back to the factory location for the ranger
and a new tail pipe. last thing to do will be swapping out the cup holder with one from an automatic.
I will update with pictures as soon as i sort them and put them in order.
Price list
donor 800.00
gaskets and exhaust manifolds - 300.00
plug wires coolant fluids and plugs and others from oreillys - 460.00
fuel rail w/injectors -75.00
ecm- 39.00
cam shaft sync- 36.00
wiring harness -150.00
O2 sensor - 33.00
reprogram -48.00
exhaust work -275
total-2216.00
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