94 Ranger engine swapping

[ThePenguinKnight]

I have a 94 ranger, 4.0 4wd, with about 309k on the motor. Pretty much all the seals are shot, and given the mileage and the costs involved in repairing the seals, I'm pretty sure swapping the engine out will be my best option.

What 4.0l motors are "drop-in" replacements? I understand Ford went to a SOHC in 95, but are those usable in my 94? Also, is there anything special about the Explorers that would complicate a swap, such as a wiring harness or whatever?

Anything I especially need to watch out for when motor shopping or doing the work?

Thanks in advance for any help.

 

[nitrofan1]

Welcome Penguin!

If you haven't visited the Tech Library before now is the time. This link will tell you all you need to know about the 4.0L and what works and what doesn't!

Good luck!


http://therangerstation.com/tech_library/4_0_Page.html

 

[ThePenguinKnight]

Welcome Penguin!

If you haven't visited the Tech Library before now is the time. This link will tell you all you need to know about the 4.0L and what works and what doesn't!

Good luck!


http://therangerstation.com/tech_library/4_0_Page.html

Ah, I guess it was 98 that they went to the SOHC, not 95.

Still, the article only partially answers my questions, indirectly. Are the motor mounts in the same place on the OHV engines through 2000? The wiring harnesses? Is every 4.0l OHV in the 93-2000 range going to bolt up with my manual transmission without issues? The vacuum lines, electrical connectors, etc.?

I'd think all that would be the same across the board for that engine, but it wouldn't be the first time vehicle engineers tried to surprise me with things like that....

Also of great importance to me: Did any of those things (motor mounts, wiring, etc.) get changed on the Explorer model? There is a promising Explorer engine nearby, but I want to make sure of what I'm getting before I invest.

Anyway, thank you. If anyone has any information regarding those questions, thanks in advance

 

[nitrofan1]

In 96 they went OBD II. 95 and older harnesses will work. Newer 4.0L's you have to use your sensors and emission stuff. Mounts, bolts etc...... will interchange. If you use 96 and newer emissions, fuel delivery and such you'll have to pull the harness and the computer's then have them flashed.

Stick with the 93 to 95 stuff. 90 to 92 4.0L's suffer from head issues. If you took care of your engine even though it have ass loads of miles I'd just rebuild it. It must be a good one to have that many miles.

 

[Yellowsplash]

Correction....95 Rangers were OBD II, while 95 Explorers were OBD I even though they contained an OBD II port under the dash (the OBD I port is under the hood).

 

[holyford86]

I have a 94 ranger, 4.0 4wd, with about 309k on the motor. Pretty much all the seals are shot, and given the mileage and the costs involved in repairing the seals, I'm pretty sure swapping the engine out will be my best option.

What 4.0l motors are "drop-in" replacements? I understand Ford went to a SOHC in 95, but are those usable in my 94? Also, is there anything special about the Explorers that would complicate a swap, such as a wiring harness or whatever?

Anything I especially need to watch out for when motor shopping or doing the work?

Thanks in advance for any help.

Unless your 94 is one of the oddballs with egr, and a cam sync 91-94 engines will be a direct drop in. 95-97 motors are pretty close to a drop in, but you will need to swap some sensors, plug the egr port in the driver side exhaust manifold and use your aluminum upper intake, with the exception of some 97 motors which used the 8 bolt crank. You'll need the flywheel or flexplate from that application to use that engine. 98-01 engines you will need to do some sensor swapping, you may have to deal with egr, you may not. the engine side of the motor mounts will need to be swapped as they are completely different than the 91-97 mounts. You will need to use the flywheel or flexplate from these as they have the 8 bolt crank.

Ah, I guess it was 98 that they went to the SOHC, not 95.

explorers went to a SOHC 4.0 in 98 but the ohv 4.0 was still an option for a couple years after. Rangers made the switch in 2001

Still, the article only partially answers my questions, indirectly. Are the motor mounts in the same place on the OHV engines through 2000? The wiring harnesses? Is every 4.0l OHV in the 93-2000 range going to bolt up with my manual transmission without issues? The vacuum lines, electrical connectors, etc.?

You will need to use your engine harness to make a newer engine work. The engine side mount plates are different on 95+ explorers and 98+ rangers but you can swap yours onto the block as the holes are still there.

I'd think all that would be the same across the board for that engine, but it wouldn't be the first time vehicle engineers tried to surprise me with things like that....

Many small changes throughout production, there are variations on quite a few things in them over the years.

Also of great importance to me: Did any of those things (motor mounts, wiring, etc.) get changed on the Explorer model? There is a promising Explorer engine nearby, but I want to make sure of what I'm getting before I invest.

yes, depending on the year.

Correction....95 Rangers were OBD II, while 95 Explorers were OBD I even though they contained an OBD II port under the dash (the OBD I port is under the hood).

I've never heard of that, but there is a ABS diagnostic connector on some explorers that looks exactly like an OBD I diagnostic port

 

[Yellowsplash]

I've never heard of that, but there is a ABS diagnostic connector on some explorers that looks exactly like an OBD I diagnostic port

I should know...I own both. The reason I say this is because even though both engines were manufactured in 95, there are a few sensors that are unique to the type of on board diagnostics that it was equipped with. So depending on if it was an explorer or ranger will determine what needs to be changed to work for your application.

 

[ThePenguinKnight]

Update: The old motor is out, and a 93 explorer motor is standing by with new seals and freshened up heads. Took me a little while to figure it all out, but it wasn't too bad. Just working on cleaning some stuff up and I'll be ready to put the new (sorta) motor in.

First though, my motor mounts need replacing. The bottom nuts on these mounts are above the front differential and CV joints, and look to be a real pain to get to. Is there a guide or process available, detailing what all I need to take loose and how to put it all back in the right place? Haynes manual isn't much help on this one, and the local Ford dealer isn't talking either....

Thanks all. Back to scouring the internet and calling every mechanic I know

 

[ThePenguinKnight]

Well, I managed to het both mounts installed. The passenger side mount went in with a clever combination of extensions and a universal joint for my torque wrench, while the driver side was kind enough to be almost a straight shot once I loosened the stabilizer bar link. I was almost overjoyed when I realized I didn't need to touch the front differential.

Now for an interesting oops: between the Haynes manual and the guy at the parts house, I managed to get a little confused about exhaust manifold gaskets, and I ended up putting my exhaust manifold on using a combination of the gaskets and a bearing grease/graphite concoction that the parts guy told me to use. After doing the reading I should have done before putting the manifold on, I realize now that I should've just used the gaskets dry. My question: is the concoction going to hurt anything, or can I leave it alone?

Thanks all.

 

[holyford86]

it probably won't hurt much but it might smoke a bit once it gets hot the first time, just re-torque the bolts once you run it and you should be fine.

 

[ThePenguinKnight]

Yeah, it smoked pretty good for a while. I'll be sure to check the torque on those bolts before I drive it.

It's been a long project. I'm more a computer guy than anything, and while I'm not a stranger to basic car work, I've never taken on something this big before. I had to stop and research things every few steps of the way to make sure everything was right, etc. I'm sure now that I've seen it, I could do it all again in half the time, but I'm hoping I never have to do it again

As an update: the engine is in, and seems to be running strong. I had to spend a good long while figuring out how to coax the motor and engine together, but they eventually started behaving. Had some trouble with the battery connections being badly corroded, but she fired up and purrs nicely.

I'm having trouble getting the power steering pressure line to seal, but I think I'm just going to put a new hose on it. The only real remaining issue I have before I call it done is that my e-brake and ABS lights are coming on, and I'm not sure why. Plenty of fluid in the reservoir, brakes were bled, and the brakes feel solid when the pedal is pressed. The only thing I can think of offhand is that the replacement proportioning valve (from the Explorer that the engine came from) is sending the wrong signals to my Ranger's computer, but I'm going to do some more research, maybe try bleeding them again.