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2.9 to a 4.0


1987 DANGER RANGER

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Hello I know that in the tech area the info is all there but I was trying to find the easiest spread type sheet. I am going from an 87 4x4 2.9 to a pre 95 4.0 from a exploder 4x4. I need to know what items I need from the slpoder for the swap and anyother piece I may need for up grade such as axles. what part do I need from the axles maybe everything that comes in contact with them? If it would help I could try and find out for sure what year the sploder is on 11032007. Any advice would help thanks.
 


swamprat

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Dont be surprised if people tell you to do a search first and read the tech articles since all your questions have been answered already in another thread or two. I am in a rare good mood so here it goes

engine
wire harness
ECU
complete EVT manual for both engines (just a suggestion for splices)
thing on core support (tired cant think)
radiator

sure there is more

axles

take the D35 off the Ex and the 8.8 rear.
swap to manual hubs if needed


You have left some details out
Are you keeping the trany?
5sp to 5sp?
5sp to auto?
auto to 5sp?


5sp to 5sp will be the easiest IMO.
 

1987 DANGER RANGER

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keeping my 5sp fm145 until I can afford to rebuild the auto. Should I keep the t-case and driveshafts from the x
 

swamprat

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keeping my 5sp fm145 until I can afford to rebuild the auto. Should I keep the t-case and driveshafts from the x

If you keep your 5 sp then you will be adding a lot of work later. I would rather do the engine and trany swap in one move. The FM145 is a weak trany so it might not hold up behind the 4.0. It will fit but is weak. It depends on how hard you wheel to how long it will last. Plus you will have to swap out the pedals and flywheels and starter.So you are using an auto engine and harness and plan to put it in a 5 sp. That might give you some wiring problems. First you will have to bypass the clutch engage to start. You will have some extra wires that you will not be using. I wouldnt keep the t-case if it is electric.(more wires to deal with and they are prone to failure). Keep the drive shaft all though you might have to modify them to use them. They are stronger than what you have. You could take them to a shop and have them modified. If you use the Ex t-case it will have a different out put for the front than you ranger i believe, that is where parts from you Ex driveshaft will come in handy.

If I was you here is what I would do.

get a M5OD to put behind the 4.0 and use the manual t-case from the ranger. That will give you a dependable rig.
 

1987 DANGER RANGER

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where do you get the M5OD. MY manual trans pedals from my ranger wont work alone with my ranger flywheel or starter. I was planning on useing my manual trans unitl I could afford to rebuild the ex's auto trans. I dont plan on getting to crazy wheeling just want a motor thats more reliable then my current 2.9
 

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the M5OD is a 5sp out of a ranger that had a 4.0 in it.
 

1987 DANGER RANGER

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Which stater will I need to use the 4.0 or current 2.9. Can I use the flywheel from the Fm145 or the one from the 90 x 4.0 and auto trans. If I cant use either flywheel what should I use, also if I cant use either starter which one should I get. What years did the ranger have the M5OD and what auto trans is in the x. thanks for all the help
 

1987 DANGER RANGER

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Still looking for the starter and flywheel answer. Know for a new one. They say you need the inertia switch from the 4.0. I'll be looking for the switch in a 91 slpoder its in the dash behind the heater control right? What does the switch look like and what does it do. In the forums it says take the EDIS module what is this what does it do and where is it. I says to take the fuel lines do they need to be taken from the fuel tank to the engin, or whats just under the hood. Anyother advise or things I have missed would be great.
 

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The fuel lines that actually hook to the 4.0 engine are different.

The 4.0 fuel lines are a complication because the 4.0 uses a fuel line setup like that used on an '89-up ranger.

'89-up used ONLY an in-tank fuel pump (a physically different in-tank pump from what you have now)
And those lines disconnect back by where your frame mounted pump is now.
On an '89-up that's where the fuel filter is mounted.

As for your flywheel/starter question I coun't make heads or tails of your
question the way you phrased it.

You need to carefully phrase where you are and where you want to go....

but in general a 2.9 flywheel will bolt to a 4.0, but won't live very long.
In point of fact the stock 2.9 clutch is marginal for the 2.9 (it was really
designed for an 88hp 2.3 with a carb)

The 2.9 starter simply will not work on the 4.0.
There are exterior reinforcement ribs cast into the block on the 4.0
that interferes with the "fatter" series wound starter motor.

So you MUST switch to a permanant magnet 4.0 starter.

with a 4.0 manual flywheel you must use the 4.0 manual trans starter
which has a shorter "nose"

If you decide to try running the 2.9 flywheel and clutch you'll need to use
the 4.0 Auto trans starter which has a longer "nose"

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That pretty well sums it up. So basicly I need to get the fuel lines from a 89-up ranger or can I use the 91 x lines. I plain on useing the stock 5sp trans and flywheel from my 2.9, until I can afford to replace the front and rear diff to the 8.8 and d35. Then I will replace the trans since I will have to replace the driveshafts for the new axles and trans. I dont want to change the driveshafts twice. Is there anyway to use the stock 87 fuel lines and just change the connections. If I have to change the lines to an 89-up ranger, where would be the best place to get the new lines.
 

AllanD

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Basically you are either going to have to replace the entire fuel line and all the components along it (essentially what I did on my swap) INCLUDING the in-tank unit
(Ugly)

OR you are going to have to splice fuel lines
(Even uglier)

I kinda cheated because I actually "updated" my fuel line system
two full years before I got around (or was forced into) doing my 4.0 swap.

If you had an '89-up your job would be limited to switching two connections.

Thinking more about this.....
Technically there is no real good reason why you couldn't modify your exsisting
in-tank unit by removing the low pressure pump and replacing it with the 95lph
pressure pump for a Mustang from Summit (or elsewhere)

You will need a short length of high pressure rubber fuel line (sometimes supplied with the pump) and on the '86-88 Ranger in tank unit you will also need to shorten the fuel pipe that the pump attaches to (the HP pump is ~3/4" longer than the Low pressure pump).

Relocating the fuel filter from it's '87-88 location to the '89-up location
(same place your frame rail mounted pump is now) has it's own benefit,
the fuel filter is FAR easier to change in in the later location.


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1987 DANGER RANGER

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So basically I cant use the exploder fuel line and I need to find a 89-up single cab ranger as a doner of the fuel lines correct. Does the fuel line have to be from a 4.0 or will a 2.9 fuel lines work. What would I need. Would I need the everything from the fuel tank to the motor including pumps. There is only one fuel pump on the 4.0 correct, and it is located in the tank. The only problems is I have a very tight budget for this swap at this time. How come everyone states this is a direct bolt in and the only time they mention anything about the fuel lines is when the swap vehicle is carbarted and not FI
 
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AllanD

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That depends greatly on what year explorer fuel lines.

And what parts of the fuel lines.

I'm trying to avoid writing a damned encyclopedia here.

The braided lines from ANY 90-94 explorer that connect to
the "garter spring connectors" down just behind the steering
box will be fine, but if your explorer is '93-94 you'll find difficulty
using the rigid metal lines that go back from there, because the
Explorer uses stainless steel lines

AND it uses the long necked fuel filter with the annoying all metal
spring lock couplers

Thus my reason for suggesting a complete set of lines off of a vehicle
closely matching your truck rahter than the explorer parts.

As for not mentioning the details? it only comes up if someone asks
and it's only an issue on the earlier fuel injected trucks, basically '86-88

Because with the EARLIER trucks that originally came with
carb engines the swapper KNOWS that they have to change EVERYTHING

And on '89-up trucks you have to replace only the short length between the fuel filter and the garter spring connectors, so again, it isn't an annoying "suprise" to anyone

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1987 DANGER RANGER

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So a 89-up ranger with a 4.0 motor fuel system from the motor to the intank pump is what I am looking for. Or splice my current fuel line put the 4.0 ends on remove the fuel pump which is on the frame rail (replace with a fuel filter) up grade the intake to the mustang fuel pump (95lph). plus the fuel line you stated earlier. The stock fuel pump in the 91 x is brand new and cant be reused (because the LPH is to low?). I am not trying to sould like an dumba$$ however it my seam LOL but to me the whole fuel issue was a surprise, my lack of research. All the info you have given me has been very helpfull
 

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