Another 2.9 to 4.0 swap?

So, recently I've been researching a good engine to swap out my tired 2.9 for... Well, I think it's about time as I went out today and found some "snot" on the oil filler cap... So, I guess my decision will have to be sped up a bit. I found a '91 Explorer with a 4.0 that only has 68k on it so I do believe that will be my donor vehicle... What I'm asking is there anything special I need to know before I do this, I've read up on it and I know I'll have to swap out my tranny and t-case, and I'll be doing an 8.8 and D-35 swap along with my engine... Any tips suggestions?

Well, I think it's about time as I went out today and found some "snot" on the oil filler cap...

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Totally normal, it's condensation. Check your dispstick/drain your oil to be sure.

thats not allthe way tru, i have snot on my iol cap and im going through water, im 100% sure i have a cracked head by a exhost port and the water is blowing right out the tail pipe, . and my oil and dip stick is A ok no water in block. not saying your wrong just wanted to add to what you said B2. so 7000 i would look in to your prob alil more 2.9 do build up snot from condisation.

you realy have nothing to lose i would dig in to that motor be fore i pulled it and started a nother project what do you have to lose?

I immediately thought that because I have had to add coolant twice already in about a months time, but I don't find any coolant at the dipstick, but this motor has a few more problems, I know it has one leaky injector (minor prob, but still have to fix it), a terrible tapping noise that only rears it's head when it's warm, sounds way louder than lifter tick, I can hear it in the cab with the A/C on full blast... The tranny isn't holding up too well either (Throwout bearing?) It makes a noise like something spinning/grinding whenever I left off the clutch. I was just kinda looking at what would be cheapest and easiest right now... this truck has to be reliable enough to run at least 100 miles back and forth from school and back every weekend, and being that I'll be in an apartment in August I have to get it finished before August, so I'm kinda in a pickle here...

get the EVTM's off ebay for your truck and the donor.they are the best electrical manuals you can get.if your truck is the single fuel pump design it will be a cake walk.

remember to take a lot of pics of the explorer engine compartment as it comes apart so it goes back the same.tear down the b2 first so the explorer setup is fresh in your mind when it goes in the b2.

when i did the swap i used all the 4.0l engine compartment harnesses and repinned the one on the drivers side so it would plug into the cab harness without changes to the dash harness.it wound up only being 8 wires different,which was mostly due to different options and the year difference.

f*@k the 2.9 you will LOVE the 4.0l and i even get 1-2 mpg better pushing around 33's

there are plenty of guys here who can help you through this,good luck!

Ok, so that's what I plan on doing, going this weekend to make sure the 4.0 starts, anybody know how to start one with no keys (that's one of the reason's it is so cheap)? And also about transmission, I know the tranny from the 2.9 will bolt up correct, but it won't hold the torque right? Would I be able to use the auto tranny (it's new) from the Explorer until Christmas? My dad said he would buy me a new transmission if I could hold out until Christmas. I'm guessing I could fab up my own shifter and linkage and stuff if I had to, just wondering if there was an easier way... thanks alot, gonna go order the EVTM as soon as I know the engine runs

Beanmachine7000 said:

Ok, so that's what I plan on doing, going this weekend to make sure the 4.0 starts, anybody know how to start one with no keys (that's one of the reason's it is so cheap)?

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the actual electrical switch that starts the truck is on the top side of the steering column under the dash mounted by two 11mm or 7/16 bolts(same size). use a regular box end wrench to get the switch off and you move the rod in and out for the positions.i did it at the wreckers to start a 92 sploder a few months ago when i was getting my donor motor.it helps to rip off some of the lower plastic so you can see up there and i took off the column plastic to ununhook the metal rod at the key end

Beanmachine7000 said:

Would I be able to use the auto tranny (it's new) from the Explorer until Christmas?

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in short i'de say its a bad idea,too much extra work.
the cpu's are specific to the tranny,auto or manual and your donor tranny harness will be a little different for each.they are all the same length so driveshafts are easy.

the way i see it you should either bolt it up to the fm-146(your tranny) with the 4.0l clutch and MANUAL TRANNY 4.0l starter,using the tranny harness on your truck,and and take it easy until christmas,while looking for the ranger or sploder shifters, boots,floor tin,tranny harness etc for an 4.0l m5od,and keep an eye out for a manual cpu(not totally neccesary),

OR convert to auto since the tranny is new and the sploder has an auto specific cpu and tranny harness(that you'd need to splice in with the neutral safety switch crap so it'll start).you'd need to use the sploder steering column,auto radiator, and pedals but no biggy.i'de almost rather do that in a b2 than a manual for the smooth power,it'd still be much faster off the line than stock too.auto's really aren't bad when you have adequite power.

good luck and take it slow,one thing at a time.
and look as many swaps up as you can in the tech library and the "other" engine swap forum.most of your questions will be answered in other peoples threads
probably won't be a ton of help but here's mine http://www.therangerstation.com/forums/showthread.php?t=6522

Alrighty... So, I think what I'll be doing is...

1. Going this weekend to check out the 'Sploder
2. Start ripping apart the Bronco this week
3. Dropping the 4.0 the weekend after the 4th
4. Riding on the old FM146 for now (Dad says he'll go ahead and get me a new(ish) M50D or buy one and rebuild (Christmas in July anyone?)
5. Do the 8.8 swap the weekend after the 4.0
6. Do my D35 swap the weekend after the 8.8
7. Finish up "Project Edgar" with a M50D/BW1354 swap the beginning of August
8. Enjoy my refreshed better than new Bronco II!

Do you think I would be able to do each swap on the weekends (all day Friday, Saturday, and Sunday?) Anything anybody see that I missed?

3 might take longer than a few days.you'll need a new shorter driveshaft and some welding for 5

Yeah, I think it might take more than a few days to swap the engines. I did the swap last fall into a 88 Bronco II but then again if I remember correctly you have a 89 and from what I hear, the wiring is a lot easier. The swap is well worth it. So far I have been trouble free with thousands of miles racking up on the odometer since I put the 4.0 in. And one thing is for sure, you will never go back to the 2.9 once the 4.0 is in. The power difference is substancial!!

Ok, about the driveshaft, I'm guessing it will be shorter because the Bronco has a shorter wheelbase and nothing about the difference in a FM146 and M50D correct? And, yes, I know about spring perches being different and shock mounts and all, I'm going to get a good friend to weld all that up... My welding skills aren't too hot, lol... Abrush, it's good to hear someone say something about the wiring being easy, lol... So I plan on pulling apart my Bronco this weekend and start parting out what's left, you guys think I should disassemble the engine and part it or just sell it for scrap, I'm sure there are people looking for parts off of it...

Haha... I just realized what I wrote about the drive shaft, lol... I'm guessing it would be correct to say it isn't a difference in transmission, but the 8.8, lol... duh!! My new shaft will fit on the M50D when I swap it out correct?

Beanmachine7000 said:

Haha... I just realized what I wrote about the drive shaft, lol... I'm guessing it would be correct to say it isn't a difference in transmission, but the 8.8, lol... duh!! My new shaft will fit on the M50D when I swap it out correct?

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the explorer front d-shaft will work if you use the explorer t-case and d35,your current shaft will work with your b2-case and d28.you'll need to shorten the rear explorer shaft if you can't use the yolks off it and shorten the b2 shaft

I plan on using my 1350 and D28 for about a week or so, just with no driveshaft, So what you are saying is that if I run the 8.8 with the 1350 I would have to have a special shaft, but when I replace my tranny and t-case I have to get another one? I'm confused, lol... The way I'm seeing it is that I may want to just keep my tranny, t-case, driveshaft and 7.5 until I get my new M50D and then swap rear axles... BTW I'm pretty sure my head is cracked, this weekend I refilled my coolant to the proper level and today I opened the hood and it was empty again (at least the the overflow tank was) and there was coolant all over the dipstick and filler cap... Thanks for all your help guys!!