5.0 Manual swap- 2002- Hurdles

[b3million]

Good afternoon, fellas.
I'm pricing out a 5.0 swap for my truck. I want to keep a manual and retain selectable 4wd capability, so I won't be doing the explorer transplant.
I had a few questions about motors, transmissions, and wiring options.
First- I understand that the 302 came with forged pistons for a select number of years until mid-1992. Was this all 302 motors or just the mustang/thunderbird variants?
Second, there's a 40hp difference between the truck 302 and the car 302 of that type of motor. Can that difference be made up with an intake swap and a tuner, or is it more involved?
Third, is there a difference in transmission bolt patterns between the truck blocks with the m5OD and the mustang blocks with the T5?
Fourth, I imagine I get around the PATS stuff by getting an older motor and computer. Am I neglecting anything there?

What I'd like to do (Ideally) is find a 1991/1992 f150 with a manual transfer case that I can grab the motor, mounts, M5OD, and transfer case from, and adapt that into my 2002 b3000. That solves any need for a custom harness/ computer and wiring hassle. Plus, it's a cheap option and reduces the need for pick-and-choose part sourcing.
The problem is the power- I want at least 225 base hp and forged pistons so I can add a supercharger later down the line. That might mean I have to get a foxbody motor and computer, which will be harder and more expensive. I want the M5OD so I don't have to adapt a transfer case to it. Either way the computer will have to come from a mustang or an f150.
There's also the option of the 351W, but i seem to recall hearing somewhere that those motors have fitment issues and never came in manual, so that significantly increases the computer hassle.
Answers/advice appreciated.

 

[85_Ranger4x4]

This in relation to a multiport EFI SBF roughly 1986+...

First- I understand that the 302 came with forged pistons for a select number of years until mid-1992. Was this all 302 motors or just the mustang/thunderbird variants?

Only the HO and I don't remember if it was just only the Mustang or not.
Keep in mind those pistons/rings are 30-40 years old, there is a good chance if they haven't been rebuilt with who knows what... they may need to be.

Second, there's a 40hp difference between the truck 302 and the car 302 of that type of motor. Can that difference be made up with an intake swap and a tuner, or is it more involved?

Cam, heads, pistons, intake, exhaust, tune...

There is some variance, Mustang makes a lot more power than truck but generally they have the same heads. Generic "car" 302 will have different heads. Cam will go a long ways which will require a different distributor and may change your firing order

Cars will have a roller cam, most mid to late 1980's truck blocks are set up for a roller but are still rocking flat tappet.

If you can find one just the engine out of an Explorer is really the best route IMO. As much power as anything, good intake that fits, arguably the best belt drive system Ford hung on a SBF and it is basically set up to fit in your engine bay from the factory. Then do whatever feels right with the electronics and transmission.

Third, is there a difference in transmission bolt patterns between the truck blocks with the m5OD and the mustang blocks with the T5?

Same pattern, use the correct separator plate/starter for whatever transmission you use.

Fourth, I imagine I get around the PATS stuff by getting an older motor and computer. Am I neglecting anything there?

Whatever your truck will need to see from the ECM to function will need dealt with. Mine didn't care, yours will care. I haven't been down that road on a truck that new though.

 

[franklin2]

I have never done this swap, but have researched it some. While the bolt patterns are the same, the truck bellhousing is larger since they use a larger flywheel. They say the car uses a smaller flywheel, so a smaller bellhousing, and it fits better at the firewall of a ranger. Unless you want to use a little bit of a body lift to help clear the larger truck bellhousing.

So if you are going to use a Mazda made for a transfer case, I guess you will have to use the larger bellhousing since it will be from a truck.