What engines will directly repalace a 2003 4.0?
 

Since my current 2003 4.0L SOHC had a meltdown (http://www.fordrangerforum.com/gener...e-tonight.html ), the most economical solution is replacing the engine as a mini-meet workparty at my friend's barn/shop. What year 4.0's will directly replace the one I have now?

I suggest a 04+(far less prone to the timing chain issues). As long as you use your existing engine/trans wiring harness, you'll only need to change the fuel injector pigtails and the DPFE pigtails on your existing harness(my 06 injectors and DPFE sensor took a different pigtail). Most engines I've seen on the engine racks have the engine harness attached to them(my 06 engine came with the entire engine/trans harness).



CRAP! Just noticed....'03. No EGR. Mkay....you can run a newer engine, my 06 is EGR but I don't know specifically what years got it and what didn't it...I know 01-02 got EGR, 06+ got EGR, in between IDK. No worries though...you can run your existing intake and exhaust manifolds to make it non-EGR. Might not even have to run your old intake...possibly use your existing EGR block off plate. And by using your existing manifolds, you don't need to mess with your DPFE sensor pigtail.

Hope I kinda helped.

Shane

If I go the route of replacing the motor, I definitely want a newer one with less miles to make it a little more worthwhile.

Also, will a 4.0 out of an Explorer or Mountaineer be identical?

The gen2 4.0 Explorer SOHC is probably the same basic engine but I know that the intake manifold and harness are different, maybe more. These also had the same timing chain problems that plagued 2001/2002 4.0 Rangers.

Too bad you're not closer. My 25K 2003 4.0L is looking for a new home.

Ok so I'll stick to Ranger engines. Will any 03-08 4.0 be a drop in repalcement other thant the DPFE stuff?

I don't know how new you can go without any problems, maybe all the way to current. Going by Shane's swap, it sounds like 2001~2006 is totally safe. Converting a non-2003 to the 2003 EGRless condition should be easy. I believe it just involves blanking off the intake and exhaust manifolds with the 2003 plugs that you already have.

Cool. I have leads on a 2005 with 35k and a 2004 with 65k. And I have a mounting army of people eager to have an engine replacement party in my friend's barn. Yee haw.

Little disclaimer from me regarding my swap: I didn't want to reuse any sensor from my old engine but the MAF, so all sensors that were different than my 01, I soldered on the 06 pigtails into my 01 harness(injectors, DPFE, believe that was it.).

Holy crap, I just found a 2008 motor with 11k on it for cheap. Can anyone give me a educated yay or nay on if there anything new and funky that won't make it drop right into the '03 other than the stupid EGR crap?

There is definitely a totally new engine/trans wiring harness on the 07+ for the new PowerPC PCM. Plenty of other possibles but I'm not familiar with the new engines. I doubt that there is anything that would keep you from swapping the long block but who knows?

Does that mean that if I keep my existing wiring and devices, the engine itself will dtop in and i can just plug stuff in? I'm not sure what is different.

Matt, use your existing harness and swap over the different pigtails.....fuel injectors, DPFE and I seriously think that's it! Marie's got a 08 and her 4.0 is just like my 06 4.0 in regards to all the sensors and pigtails and such. I know you know how to solder! (at least I think I know you do. haha) The only area that's a pain with pulling the harnesses, is you've gotta pull the intake manifold off the engine to unplug the temp sensor pigtails at the thermostat housing. I know on my engine swap, I had to carry over the incoming fuel line into the rails from my old engine.....evidently the newer trucks have a different quick coupling system on their fuel lines.

You won't be able to run the engine/trans harness from the new motor that Bob noted above.

Couldn't I just make the splice for the temperature sensor wiring elsewhere that doesn't require removing the intake manifold? Or is that an easy enough task to not really matter?

yeah yeah yeah....lol. The location of the routing of the wiring makes it a pain and I said screw it. The wiring snakes around the heater hoses and vacuum lines just under/behind the throttle body and the passenger side front valve cover, then is tied up like crazy in the rest of the harness with the injectors and such. But your a compitent guy, I know you can make something work. I got frustrated and said forget it...i'm gonna have a grand total of 60 solders in my harness. lol. I had to do alot more than what you've gotta do...I learned from my mess up.

hell just drop an old 327 or 350 in it get more power lol