2003 4.0 SOHC Swap - Auto Trans Donor Vehicle to my M/T Truck

[Jim_Philly]

I'd like to replace my 192k engine with timing chain rattle with one from a lower-mileage vehicle. I have the M5OD-R1HD manual transmission. If the engine comes from a donor vehicle with an automatic transmission, are there computer/wiring mods that will need to be done? Any other considerations (mechanical etc)?

I will limit my search to M5R1 donor vehicles if it's too much of a pain otherwise.

 

[RonD]

That would be fine, no changes to engine needed if they are similar years, engines are not transmission specific
You need to put your flywheel on the other engine if it was from an automatic

But..................you have to pull the engine out to swap it and to put in new timing chains and tensioners
So why not just put in the updated timing chains and tensioners in your current engine instead of putting in an unknown used engine?

Its cheaper and safer to go with your engine

 

[Dirtman]

Yea I wouldn't put ANY 4.0 sohc engine in without putting brand new chains and tensioners on it. Installing one with used chains makes about as much sense as wiping before you poop...

 

[Jim_Philly]

To clarify, I was going to buy a lower mileage engine and install new tensioners/chains/casettes on THAT engine. Plus valve cover gaskets etc while I'm at it. My truck has 192k miles on it and is unknown to me as well because I just purchased it. I knew it had the rattle when I bought it, but it's the hard-to-find 03 FX4 Level 2 with manual transfer case and has virtually no rust (remarkable for here in PA) so I'm willing to do some mechanical work. Got it from a used dealership though so unfortunately I couldn't speak to the previous owner (one-owner vehicle, amazingly).

 

[RonD]

Engines are usually good past 400k miles after 1990 or so with the new materials used
So keep that in mind
If you drive 15k a year that's 13 more years on current engine
Your current engine was only used 12k a year, 200/17 = 11.7
If you find a 100k used engine that adds 6.5 more years, so close to 20 years

13 or 20 years is alot on a chassis, especially in your area, as you said

If you keep vehicles until they are scrape then it may be worth it to find a lower mile long block
But if you think you would sell it within 10 years, I would just put new chain kit in what you have now

 

[Jim_Philly]

Thanks, Ron!

Another dumb question - my particular engine does not have an EGR valve from the factory (I had to do a lot of searching to confirm the previous owner didn't just do an EGR delete). If I get a donor engine with an EGR, is it just as simple as taking the EGR stuff off and re-using the blank plate on the intake from my current engine?

I ask because I have a 2002 4.0L FX4 available to pick from, and it has the EGR (like most other 4.0's out there). I haven't done enough research on EGR/emissions/vacuum lines yet.

 

[Dirtman]

Yes just remove it. You just can't use an EGR equipped engines computer on a non EGR engine or vice versa. If you're keeping your current computer you can just ditch the EGR stuff and block it off.

 

[RonD]

+1 ^^^

But it is odd there is no EGR system on a 4.0l SOHC
I know the 3.0l lost them around 2002
Ford was playing around with exhaust valve timing so exhaust valve stayed open a bit on intake stroke to suck in exhaust gases so no EGR needed

EGR prevents the spike in the toxic gas, NOx, emissions when engine is under load and cylinders heat up
The exhaust gases slow the burning of the air/fuel mix which lowers the temp in the cylinders
Because of the lower temp it also helps avoid pinging/knocking on 87 octane fuel

 

[Jim_Philly]

Check out the vacuum line diagram on the rad support on my previous 2002 vs my 2003.. dunno why Ford did it. From what I can tell it was 03 only.

2002 (EGR):

My 2003:

Photo showing blank intake manifold filler plate and unused solenoid mounting bracket holes:

 

[RonD]

Good info

Thanks