Project ST- yet another V8 swap....

[RangerSVT]

Yes, the engine to vehicle plug (black 42 pin plug located on top of the intake) is the same and plugs right up, the plug I'm talking about here is the rectangle plug for the altenator harness, located under the ABS pump on the fenderwell. I'll get a couple pics of it today, I thought I took a pic of it, but I guess I didn't. Thanks for bringing that up. The harness is a little tight to fit, but there is room in the harness. Since I have both male and female plug ends, I may make a short extension to go between the plugs so it will have more slack in it (I'm picky about the way it is, it will work in its current configuration, but I just don't like it)
SVT

 

[Josh40601]

Thanks dude

 

[RangerSVT]

SWAP COMPLETE.....almost Ok, back to the beginning of today...
I took a couple shots of the 42 pin harness, and what I needed to do to get some slack in the harness to mate the two plugs together...

Along the fenderwell behind the ABS pump the harness is attached to the inner fender by a bolt. I unbolted the tab securing the harness to give me the needed slack. This was temporary as I had intentions of making an extension plug to give me the necessary slack (More on this later)...

Here is what the throttle cable looks like that passes through the firewall. There are two clips 180* from each other that release the cable and allow it to be removed...

Here is the 5.0 cable installed..

After some trial and error I found out the 1356 tcase I intended on using will not fit the wider explorer framerail like I thought, so I had to resort to using the stock explorer 5.0 AWD case, the 4404. For now I will not install the front shaft and just have rear drive. I will source the much larger 4406 and swap that in. The good news is the the trans cross member is a bolt in swap, no mods were needed...

The 4404 tcase is about 1.25 inches longer than the 1354, but the V8 trans is 1.5 inches shorter than the ranger trans, so my driveshaft fit with no mods. The one thing I did have to do was swap tcase output flanges. For some reason my tcase, which was not the original ST's case, was swapped out at some point in its life for a smaller flange. I either had to swap out driveshaft flanges, or swap out the output flange on the tcase. One nut and 30 seconds later, the flange was swapped. Here is the 4404 flange on the right, the 1354 flange on the left. Both share the same size and spline count, so they were swapped...

So except for bolting the hood and exhaust on, the swap is done (kind of). Dropped 5 quarts of ATF Merc 5 to get me started, dropped the old oil out, slid on a new Motorcraft 820S oil filter, filled her up with Castrol 10w30 (I'm gonna give her some hell the first few hundred miles getting used to the new power, and having fun while doing it, so I went with a little heavier weight. Gave it a once over and checked everything, hooked up the battery, everything is good. I slide into the cockpit with big time pudding face like a teen going to Hef's house. I turn the key on, look at the gauges and then........uh oh!!! I have oil pressure before starting the motor This ain't good, not at all!! I shut the key off, and take another look at the altenator plug. A closer inspection tells the tale. A couple of the wires are not matching up. I took a quick look at it the first time and seen a couple of the outer wires matching up and just thought they all did. So at this point, I started pinpointing my wires. I got all of them identified but there is another problem. The 4.0 altenator harness has oil pressure and the altenator wires going thru it, the 5.0 doesn't. After another quick look at the 5.0 altenator and following the harness, it goes to the 42 pin plug. Great, now I got to identify and pinpoint the 42 pin plug on both the 5.0 and 4.0 sides. I also realized when I pulled the 5.0 that it has a low oil sending unit on side the oil pan, but I didn't pay attention to the 4.0 not having it. So after a couple minutes and my firewall by the brake booster looking like this...

...and pulling the 42 pin harness apart about a foot past the plug...

I now have identified the colors of both the 4.0 and 5.0 vehicle side of the 42 pin plugs. I've found 14 mismatches that are either different color wires on each end, or are blank on one side with a wire on the other. So now I'm needing a 42 pin pinout for both a 99 explorer 5.0 and the 2002 sport trac with a 4.0. Apparently in 2001 Ford switched the wiring around. When I did the V8 swap in SVT, both SVT and the donor was plug and play. I know I can trace the wires down and ID em that way, but I know someone has got to have this info sitting somewhere. So this is where I'm at right now. I figure I have another day or two of ID'ing the pins before I can continue Good thing I know electrical...
SVT

 

[Kage]

Wow, you're knocking this dude out quick!

 

[RangerSVT]

Thanks Ben Yeah, I got ahold of a guy on ef that has the factory service manuals for both the 99 and the 02, should have them by mid day today. For now I will work on the exhaust. Once I get my tuner back (hopefully end of this week, beginning of next) I can delete the cats and go to a bigger exhaust. Time to open up the shop so I'm off here for now...

SVT

 

[Josh40601]

Sorry to hear about all the bugs buddy.

Over on Rangerpowersports.com there are a couple guys running 5hos in newer rangers. May be worth digging around. Maybe someone did the swap on an 01 and they wrote up how they got around the harness issue.

 

[Josh40601]

I also wanted to ask you what you were doing about the ABS pump once you o to solid axles. Just bypass it completely? Will this cause any issues?

 

[RangerSVT]

It's actually bypassed electronically right now. I can still have rear abs if I want it as the 60U has the tone ring and sensor already in the housing. Very doubtful I will keep it since there is a possibility this will take an occasional break from DD/Tow Rig duties and get wheeled from time to time...

SVT

 

[Josh40601]

Oh ok.

 

[RangerSVT]

Not much to report today. I got my wiring diagrams, but not all the info I need is there (didn't get complete diagrams, only partials) I have half of the wires figured out that I need. I had cut the exhaust from the donor in between the first and second set of cats, and I installed the exhaust pipes from the manifolds to the trans X-member. Tomorrow I will fab a Y pipe to connect the two banks into a single 3.5" pipe, about 2 or 3 foot long into my flowmaster single chamber muffler and then do a side exit. Why 3.5" you ask? Your gonna laugh at this one, but I don't have any 3" left over from SVT's exhaust, but I do have a driveshaft that I cut the yoke off of that was bad. I had intentions of replacing the yoke, just never did and found another driveshaft to replace it. I measured the tube size, and its 3.5" diameter, since my muffler is 3" in/out, it'll work, plus give me a little better flow than the single 2.25 I was gonna use, since thats the only other pipe I have left for exhaust. Should sound ok...I'm also going to dive into finishing the wiring. I'm hoping I can finish it. I know I can get at least half of it done since I've already got that much figured out. Also plan to use the 5.0 vehicle side of the 42 pin connector and long pig tail so I can have the slack it needs and look better doing it. The sport trac has the 42 pin harness running under the brake booster, the 5.0 runs over it....Anyways, more progress tomorrow, providing the rain holds out
SVT

 

[RangerSVT]

Oh yeah, I did manage to get one pic of what a quarter of my day involved...

SVT

 

[03ranger30]

You are moving right along, great work!

 

[RangerSVT]

Well, today my day started out looking like this...

...and this...

....And a little of this...

Can you tell I'm doing a little wiring?? So, with the help of a member on EF, He's been getting me diagram after diagram after diagram. I've got about 3/4 figured out, and I'm finished the altenator harness plug. Turns out, the only thing running through that plug now is the AC clutch and Starter solenoid wire. On the 5.0 harness the low oil sensor also runs through this plug, but I'm not running that circuit, so I pulled the pins from the engine side the harness. I also had to pull the pins for the oil pressure gauge, and the altenator output to dash gauge wire out of the altenator plug to be installed in the 42 pin plug. Here I am pulling the pins out of the altenator plug..

Putting the plug back together after re-pinning...

Here is the plug re-pinned and finished.....

I have about 14 wires to re-pin on the 42 pin plug, and I have about 40 wires to cut and lengthen (I'm extending the 42 pin plug to reach the engine harness, running the harness the way it was run in the explorer. I also got the AC high pressure switch wired....

Not much else was done. Tracing wires is time consuming, IDing wires is even more time consuming. But in the end, it will all be worth it. I hope to have the wiring done by sunday afternoon, monday at the latest. I decided not to do the exhaust, as I don't have a bender, and my limits on my pipe selection would leave parts of the exhaust looking hacked, and I don't want that. So some time next week I'll make a trip to my buddies shop to do my exhaust, side exit style. Thats kind of my signature for all my v8 swaps I've done, I've always side exited the exhaust in front the rear tire, just makes it sound like pure sex!! Hope to have better updates tomorrow....
SVT

 

[RangerSVT]

Got an update...

http://static.photobucket.com/player.swf?file=http://vid589.photobucket.com/albums/ss340/imvfdfirechief/st%20build/VIDEO0003.mp4

Still got to extend the harness(getting ready to start that now) and wrap everything back up...

SVT

 

[Bennybooster]

Nice, I bet its going to be fun to drive now