2002 Ranger 4.0 sohc 4x4 5 speed engine swap

[32180 Ranger]

Hi everyone, I’m about to swap my 02 4.0 with a 06 4.0. I’ve read I’ll need to use the intake and injectors off the 02, what is the difference? I also heard the intake will need to be from the 02 even though by looking at them they look the same. Can someone give me some advise what actually needs changed? Thank you in advance.

 

[RonD]

Welcome to TRS

No, no one will be able to tell you what changes Ford did from 2002 to 2006 on the Ranger 4.0l SOHC wiring, not how Ford, or any car maker, works, lol
Ford sometimes changed connectors on wire ends to match a new sensor or type of injector, but for the most part it should be exactly the same, swap away

You should replace the Knock sensor if you have the lower intake off, known issue
Also rear main seal anytime you have access to it on ANY engine

The 4.0l SOHC plastic thermostat housing was known to leak and/or crack, you can get a metal housing now if you want
2002 computer may need two temp units on thermostat housing, 5 volt sensor and 12 volt sender
2006 may only have the one 5 volt sensor, as 2006 Ranger has a Digital Dash/Cluster
You need BOTH if that's the wiring for 2002, so swap housings

I would swap in 2 NEW motorcraft long chain tensioners, just so you can start the clock ticking on changing them in 100k miles, or if replacement engine is at or over 100k miles then they are do to be changed in any case

 

[32180 Ranger]

Thank you so much that all makes sense. I’ll give you a update. My 15 son is doing this swap for his first truck.