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  #1  
Old 05-07-2010, 09:03 PM
euroticcustoms euroticcustoms is offline
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Default 98 Ranger 4.0 to 97 Explorer 5.0 swap & keep 5spd

Hey guys, this is my first tech post to the forum. I've read the tech articles at The Ranger Station and searched this forum, but I'm still a little confused. Anyway, I've got a 98 Ranger 4.0 5spd 4x4 and want to swap in a 5.0 from a 97 Explorer and keep the 5 speed and no PATS. I work for a car lot and have a good parts source. They're willing to trade me a 97 Mountaineer 5.0 with 146K for my 4.0 + $100. Helluva deal IMHO. Anyway, I think I can use the 97 engine, manifolds, and mounts but here's where I get confused. Which ECM/wiring harness, will I need? Can I stay away from the PATS and also keep the factory fuel pressure (56-72 psi)? I'm a good mechanic, I just can't quite grasp all of the variables of this swap. Any info would be greatly appreciated.
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  #2  
Old 05-08-2010, 06:52 AM
rwenzing rwenzing is offline
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Default Re: 98 Ranger 4.0 to 97 Explorer 5.0 swap & keep 5spd

Quote:
Originally Posted by euroticcustoms View Post
I've got a 98 Ranger 4.0 5spd 4x4 and want to swap in a 5.0 from a 97 Explorer and keep the 5 speed and no PATS......Which ECM/wiring harness, will I need? Can I stay away from the PATS and also keep the factory fuel pressure (56-72 psi)?
From a fuel system perspective, the easiest to use in a 98+ Ranger is the 99~2001 5.0 Ex. The problem with those years is that the 98~2001 Explorers have PATS.

If you want to use a 97 Ex 5.0 engine and also have 65PSI Returnless, you'd need to swap to the 99~2001 5.0 engine harness, injectors, fuel rail w/damper, PCM, CMP sensor, Synchronizer, EGR system, etc..... and then you'd still have PATS anyway.

If you want to use the newer Returnless system, it should be possible to get a custom tune written for the PCM to eliminate PATS.

Ok, going in the other direction... To convert your Ranger to the 30~40 PSI Return Fuel setup of the 97 Ex, you would need to add a return line and possibly a fuel pump assembly to make things easier.

~~~~~~~~~~~~~~~~~~

You cannot use the original 4.0 M5ODR1 transmission with the 5.0.

One option is the M5ODR2 from the F-series. If you use the correct version, it will bolt to a 5.0 and it is compatible with the Ranger's hydraulic clutch plumbing. An R2 from a 97~03 F150 4x4 w/4.2 V6 puts the transmission shifter in the ideal position for a Ranger and the bolt pattern matches the 5.0 (metric holes in the bell need to be opened up very slightly to match the 7/16" bolts used in the 5.0 app. This is a simple mod that takes about a minute).

1996 and earlier R2s from the F150/250 4.9/5.0 would put the shifter stub under the dash and require shifter mods. This 96-back trans/extension housing is also about 1 1/2" longer than the 97+ R2.

Any R2 used with a 302 needs the 50oz 164T flywheel, 11" clutch/pressure plate and starter from a 96 302 F150/250 or equivalent. The 5.0 Explorer auto starter will not work.

An M5ODR2 won't bolt up to the stock Ranger BW1354 t-case without adding an expensive adapter from Advance. Most full size transfer cases will bolt directly to the M5ODR2 extension housing but most are also a very tight fit under a Ranger.

I have a manual shift BW4406 from a 97~03 F-series in mine and it is the same pattern as the M5ODR2 ext housing. The fit is very close to the DS frame rail and the nose of the fuel tank. It worked in a Supercab but I'm not sure if there is enough room in a reg cab chassis.

Odds are that driveshaft mods would be needed front and rear regardless of the engine/transmission/t-case combo.

4x4 definitely adds another dimension to V8 Ranger swaps.
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2003 FX4 Level II, Supercharged 5.0L V8, Headers, Duals
BW4406 manual transfer case, Aussie Locker, Torsen L/S, 4.10's
Bilstein 7100 rezzies, Cadillac/Mustang rear discs, Duff traction bars
Keypad Entry, Lock LEDs, ABS switch, sway bar discos
Heated seats, Explorer EATC, Trip Computer and consoles

2003 XLT 2.3L M5OD-R1 reg cab, 2011 Taurus SEL, 2016 C-MAX Energi Plug-in Hybrid
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  #3  
Old 05-08-2010, 09:01 AM
mr cribb mr cribb is offline
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Default Re: 98 Ranger 4.0 to 97 Explorer 5.0 swap & keep 5spd

wow I have been looking for this kind of info that is this in depth. I have asked and read and found nothing of this caliber for info. Good post. This should qualify as a sticky IMO, I know there is more than just me who likes to row gears.
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1994 sun faded (New Mexico/Texas truck) maroon, regular cab, 2.3 5 speed & 3.73's. Bought w/ 227k and climbing.
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  #4  
Old 05-08-2010, 11:43 AM
euroticcustoms euroticcustoms is offline
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Default Re: 98 Ranger 4.0 to 97 Explorer 5.0 swap & keep 5spd

Awesome amount of info rwenzing. Man that really helps out a lot. My truck is a super cab. I guess I'll go ahead and put a 2" body lift on it, get the 97 5.0 and ECM. The same salvage yard has a trans and manual t-case from a 01 F150 with 77K miles on it for $950...that puts the total drivetrain cost to $1450 - $400 for my engine. I'm going to check monday and see what kinda swap he'll do for my tranny and t-case. Next obstacle - driveshafts; I'll just have to wait and see what happens once the drivetrain is in. Also, I was reading on The Ranger Station about pulling the sending unit out of the tank and putting in a 45 psi regulator...a custom tune MAY be out of the question, so I'm going to try to get away with a non PATS ECM. I've got next to nothing in this truck, just trying to fix it up to see how little I can have in it by the time I'm done. I'll keep the board posted with my progress. Thanks again buddy.
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  #5  
Old 05-08-2010, 01:36 PM
rwenzing rwenzing is offline
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Default Re: 98 Ranger 4.0 to 97 Explorer 5.0 swap & keep 5spd

Quote:
Originally Posted by euroticcustoms View Post
The same salvage yard has a trans and manual t-case from a 01 F150 with 77K miles on it for $950...
Be sure that the donor truck is a 4.2 V6. The R2 behind the 4.6 V8 uses a different bolt pattern that is not compatible with a 5.0L. Also be sure to get the transfer case shift linkage, upper and lower boots, shifter and knob

Quote:
Originally Posted by euroticcustoms View Post
Next obstacle - driveshafts; I'll just have to wait and see what happens once the drivetrain is in.
I used an unmodified stock front driveshaft from the same style F150 that supplied the 4406 manual transfer case. My current transmission is a 4R70W automatic but the M5ODR2 is supposedly the same 28" overall length. If so, your front shaft should be the same length and you might be able to get it from the same donor. A conversion u-joint can mate the F150 shaft to the Ranger front diff.

Due to large size of the 4406 and the different slip yoke, the rear shaft will have to be shortened and reconfigured.

Here's what I used for driveshafts:

Quote:
Originally Posted by rwenzing View Post
Shortened Ranger rear shaft and stock 2003 F150 front shaft:




The internal factory Ranger slip yoke was cut off and a new fixed yoke welded in by a driveshaft specialist. Then a 2006 Expedition slip yoke was added before the assembly was balanced. The genuine Ford yoke is the right size for the F150 BW4406 transfer case and it was only $19 brand new on eBay.




This is the conversion U-joint to match the F150 front driveshaft to the stock pinion flange on the Ranger's D35 diff. Otherwise, it is a straight bolt on when using the BW4406 transfer case.

__________________
2003 FX4 Level II, Supercharged 5.0L V8, Headers, Duals
BW4406 manual transfer case, Aussie Locker, Torsen L/S, 4.10's
Bilstein 7100 rezzies, Cadillac/Mustang rear discs, Duff traction bars
Keypad Entry, Lock LEDs, ABS switch, sway bar discos
Heated seats, Explorer EATC, Trip Computer and consoles

2003 XLT 2.3L M5OD-R1 reg cab, 2011 Taurus SEL, 2016 C-MAX Energi Plug-in Hybrid

Last edited by rwenzing; 05-08-2010 at 01:44 PM.
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  #6  
Old 05-08-2010, 09:59 PM
Yrac Yrac is offline
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Default Re: 98 Ranger 4.0 to 97 Explorer 5.0 swap & keep 5spd

Outstanding info, Bob. Thanks....
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2.9 5spd 180,000 miles
Crappy Paint, Worn Parts,
Fix'em as they Break
when Nowhere is Now Here
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  #7  
Old 05-11-2010, 03:48 PM
euroticcustoms euroticcustoms is offline
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Default Re: 98 Ranger 4.0 to 97 Explorer 5.0 swap & keep 5spd

Awesome news. I just talked to Mark Nettles at Elk Valley Salvage in Sutton WV (304)765-3228. He has a 97 Mountaineer with 144K miles on it, and an 01 F-150 4.2 5spd with 77K miles on it. Mark says that he'll swap me EVERYTHING I need...ecm, cruise cables, throttle cable, driveshaft, etc. for all my stuff and $500. WOW I'm freaking exstatic.
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  #8  
Old 05-11-2010, 05:05 PM
euroticcustoms euroticcustoms is offline
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Default ECM question

Just wondering...would an ECM from a similar year F-series with a 5.0 5speed work? The Explorer ECM is going to be programmed for an automatic. Any good ECM gurus out there?
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  #9  
Old 05-12-2010, 04:12 AM
rwenzing rwenzing is offline
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Default Re: 98 Ranger 4.0 to 97 Explorer 5.0 swap & keep 5spd

Last 5.0 5-speed F150 was 1996. The F-series is distributor but Ex 5.0 is coilpack and cam positon sensor instead. I think it could be done by swapping in the F150 PCM, distributor and engine harness to the Ex engine but there would probably be other complications to work through. Some say that the distributor interferes with the Ex fuel rail but I don't know for sure.
__________________
2003 FX4 Level II, Supercharged 5.0L V8, Headers, Duals
BW4406 manual transfer case, Aussie Locker, Torsen L/S, 4.10's
Bilstein 7100 rezzies, Cadillac/Mustang rear discs, Duff traction bars
Keypad Entry, Lock LEDs, ABS switch, sway bar discos
Heated seats, Explorer EATC, Trip Computer and consoles

2003 XLT 2.3L M5OD-R1 reg cab, 2011 Taurus SEL, 2016 C-MAX Energi Plug-in Hybrid
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