Hey guys, I figured I would let everyone know that I finally got around to starting a Swap FAQ, since more & more people seem interested in swapping in a 4.0.

I know its still pretty rough, Ive only been working on it for a few days, so I know it still needs a lot of info in it, but I thought I would let everyone know, so that I might get suggestions, and have people point out errors & things like that.

Anyway, here is the link to the FAQ:

4.0 Swap FAQ (http://www.rangerpowersports.com/tech/40/swapfaq.shtml)

Looks good Adam. The only thing I see that you might want to change is the years the 4.0 was available in. The 2000 Explorers came with the SOHC, the OHV wasn't available.

Ah, thanks for pointing that out, Mike. I figured that somewhere I would have an error like that.

Adam,

You left out some important stuff about the swap, like engine and tranny details that will interchange and exhaust differences. Check out the new post on a swap and you'll see what I mean.

Later Doug904.

Which swap post are you talking about, Doug? And Im not surprised I left stuff out. Im still working on it, but once again finding the time to work on it is in short supply at the moment.

Originally posted by Doug904
Adam,

You left out some important stuff about the swap, like engine and tranny details that will interchange and exhaust differences. Check out the new post on a swap and you'll see what I mean.

Later Doug904.

And don't forget the Mazda Navajo :E

Guys,
Can anybody tell me if I can take a 99 4.0 OHV, strip it down to a long block and put my 91 parts back on(Intake,exhaust,coil pack, wire harness, etc)? Will that work? Is the tranny bolt pattern the same? Will the A4LD bolt up? I would like to get this motor from a guy and its out of a 99 and it looks brand new. It looks like they bought it(Explorer) drove it off the lot and wrecked it. Any help would be appreciated.

No, unfortunatly it wont swap over. If the engine came from a 99 Exploder, then its an SOHC 4.0, not an OHV.

I just worked on updating the 4.0 Swap FAQ. If you guys would take a look at it, and make sure i didnt mess up anything.

Also, I had a few things I wasnt real sure about, that i mentioned in the FAQ. If anyone has answers for those things, let me know so I can fix it.

I have the 2.9L and i'm thinking about the 4.0 swap. Are you saying that i cannot swap my stock manual tranny w/ the 4.0 or can it be done with small fabrication changes to the mounting locations? I own an 87 ranger 4x4. Is it also possible to swap transfer cases? Are all 4x4 manual steputs push-button or does it still include the 4x4 shifter?

i have a b2 and when the stock 5 speed was in need of repair i swapped in a t-5 out of a mustang 5.0. ... about a year after that i put in a 4.0 and used the 2.9 bellhousing, flywheel, hydralic clutch and throw out bearing ... the cross member was moved when i swapped tranny's and it is in the same place with the 4.0 as it was with the 2.9. ..... as to your other questions i have no idea except that your tranny might be able to handle the torque or the 4.0 .... bye the way i am supercharged now and i am still running the 7.5 rr

does the T-5 accept a transfer case or will i have to look at a 4 speed?

Yes, a T-5 can be used w/ 4wd, but it requires a special tail housing for it to mate to the transfer case.

i have a 1999 ranger 3.0, im thinking about swapping to a 4.0 about how much time does it take for the swap? and is it worth it?

I'm in the same boat as Sweet n Lo. I found a great deal on a 4.0 but the only thing is, I think I want to beef it up a little for the hauling duties I want to tackle with my Ranger.

Adam Baker,
Yes the OHV was available in 99. I looked at the truck myself. I now have the motor sitting in my garage with a 410 cam and maybe a Eaton M62(If I can get the brackets done in time).

Originally posted by godsmack6859
I have the 2.9L and i'm thinking about the 4.0 swap. Are you saying that i cannot swap my stock manual tranny w/ the 4.0 or can it be done with small fabrication changes to the mounting locations? I own an 87 ranger 4x4. Is it also possible to swap transfer cases? Are all 4x4 manual steputs push-button or does it still include the 4x4 shifter?

I was wondering the same thing. Except I have a 2.3l 5 spd no 4x4. I'm confused. Can I get everything described in your article or not? Engine, tranny, etc. etc.

godsmack6859, A 2.9 tranny will bolt for a 4.0. How ever, its a lighter duty tranny, not designed for the increased power & torque put out by the 4.0, which means you would run an increased risk of detonating the tranny.

darangerman, I dont understand your question. Nothing from a 2.3 will work when doing a 4.0 swap. Beyond that, I dont know what your asking.

I have a 1995 B3000 and I want to swap a 2001-2002 210hp 4.0l in my truck. Do i need to know something before I start my swap.

Thanks for the information

I understand the 94 4L uses a unique cam sensor. Can I install a 4L from a 92 Explorer (had an automatic - mine is 5sp) since it has a different sensor? Will I need the computer from the explorer or an after-market computer for this combo?
Thanks

My suggestion would be to get the engine, computer & wiring harness for that specific engine, that way there will be fewer problems.

I have a 87 ranger with a 2.9 with a 5spd I just pick up an 93 4.0L form generis (great guy) I was wondering if the engine compartment wiring harness from a 90 to 92 with swap right in to the fire wall and fuse panel Or will I have to take the complete dash and tail light harness and upgrade the complete system.

Thanks

I honestly do not know if the dash harness is compatible w/ the underhood harnesses. As for the tail light/fuel pump harness, I would definatly grab that, since Im pretty sure that the end of your stock TL/FP harness will be pinned differently than the 4.0 harness. That one thing was something that caused me a ton of headaches when trying to get my 4.0 started.

sup all im doing the 4.0 sohc swap with an auto trans and was wondering if i needed the steering or could i use an after market flo shifter . anyone need parts for a 2.5 froma 2000 ranger 2wd or front suspension froma 98 exploder sport 4wd and transfer case let me know

flo shifter? you willl need the ps pump, lines, bracket and reservoir off the SOHC, this however is the FAQ for an OHV swap, the earlier 4.0

Since your truck is newer than 95, pretty much all the stuff covered for an OHV is the same for the OHC, as far as what is required to do the swap.

Originally posted by Adam Baker
godsmack6859, A 2.9 tranny will bolt for a 4.0. How ever, its a lighter duty tranny, not designed for the increased power & torque put out by the 4.0, which means you would run an increased risk of detonating the tranny.

I have to disagree with you I am using a 5 speed (mazda) tranny from a 2.9 and the only difference between the 4.0 tranny is 1st gear is higher than the 2.9 1st gear other than that they are same. If you don't believe me talk to the tranny master himself who rebuilt one for me :E

I have a 98 Ranger witha 2.5L 5 speed, and I came across a friends dad who is selling a OHV 4.0L w/ the automatic transmission, out of his 99 Ranger for 800 bucks. I know this is a steal. It was said to have about 80k miles, and was babied. This guy is an engineer and now has a 427 in his 99 Ranger. Anyway I have a few questions.

Right now the 4.0L has no power steering pump and no alternator... All the bracketry is still on the 4.0L, however the main accessory components must have went back in the 99 ranger and were made work with the 427.

Anyway 1st question is: Will the power steering pump and alternator off of my 2.5L bolt in to the 4.0L bracketry?

Both Alternator and P.S. Pump looked very similar in the way they bolt up, so i ran the numbers and everything seems to match up. However it was stated in the 4.0L FAQ that no parts will work. Anyone know any differently? Will I need to aquire any differeent alternator wiring for the 4.0L, or different power steering pressure and return hoses?

Secondly, My 98 2.5L has a 5 speed behind it, that means big hole in flloor once automatic goes in. I really dont want to get an automatic transmission column unless I have to. Could a Floorshifter be used? If so, any one in particular? I like the idea of a floor shifter.

Lastly, I want to verify everything that needs to be swapped out and upgraded for the 4.0 to perform the way it should.

So far the only other things I can think of off hand is:
Im sure of: 4.0L EEC(I belive guy w/ the 4.0L still has it), V6 Radiator, Radiator hoses, 8.8 Rearend...

I'm Questionable about: Alternator wiring? Power Steering Pressure and Return Hoses? Driveshaft? Throttle Cable? Other engine wiring? Tons of vacuum lines? Emissions hoses and what not? Transmission floor shifter?

Is there anything else that i am totally missing? Any thoughts or tips on my swap. I would appreciate any in dept knowledge concerning my topic. Any help would be greatly aprreciated.

Thanks,
Chris

not sure about he wiring or power steering lines....but i will say yet to getting the throttle cable. i know the 4.0 is longer than a 2.3, but not completely sure of the 2.5 but i would say yes. basically anything and everything touching the engine is needed.

What about mounts and crossmembers? Did it just bolt into the 2.9 truck? How about the driveshaft?

The 2.9 engine mounts will work w/ the 4.0.

As for the drive shaft, Im not sure. WHen I did my swap, I went w/ a T-5, and my stock driveshaft woudlnt work, as the slip yoke was too small. However, if I had stayed w/ an A4LD then its possible that it would have worked, but I dont know.

The 4.0 OHV was available in 99 Explorer Models. Believe me, I know. lol

yea, im in the process of getting a 98-2000 donor car for my 99 2.5L ranger. i was lookin at one that had a shatterd tranny ( dont know how he pulled that off ) and the drive shaft was bent, the crank and the engine components are completley safe still. i was wondering if i should take all the rear end and off and put it on mine. im already gonna takethe engine and the ecm and the wiring.

but im wondering if say, a 99 3.0 manual will fit right on and if the drive shaft will work too. and also if anyone knows of any bigger lift cams i could get. any help would be appreciated

I currently have a Toyo Koygo manual transmission (5-speed) in my '84 B2. I have my eye on a '92 Explorer 4.0L donor vehicle that has an automatic transmission. Will the automatic transmission mount up to my transfer case?

We are doing a 4.0 ohv swap from a 98 expo to a 98 ranger. What all do we need to swap in order to do this swap. We have changed the main harness from the firewall to the engine as well as the headlight harness.
We got the motor and tranny in and everything pluged in fine.
Do we also have to do thew TL/FP harness? We tried running it without and everything pluged in fine. Motor would not start but it turned over.
There is a elec control/computer thing inside the truck behind the stereo on the passanger side and it started smoking so we disconnected the battery. What is this box? Does it have to do with TL/FP harness? We are not getting any fuel pressure so I am guessing we need to change the TL/FP harness.
We changed the fuel pump and now we are stuck.
DOES ANYONE HAVE ANY IDEAS??? WE NEED HELP!!!!

I'd change both harnesses. Its possible that the connectors could be pinned differently.

I'd very highly recommend getting an EVTM to help w/ the swap.

As for the smoking box, I'd bet thats probably the GEM module.

We figured out what the box was. It was the rear antilock brake controller. So that is not really needed right? We dont care about ABS since the truck is going to be a pre-runner. Alright we will try changing that harnessand we will let you guys know if we get it started, cuz we might need some more ideas.

Do we need to change over for the PATS key? The 2.5 did not have the key and the engine just keeps cranking. We know the fuel pump is working but we think maybe the injectors may not be firing. Any more ideas?

I'm doing a 97 2.3L to 4.0L swap. stone02 you seem to be doing the same thing. I have been paying attention to your problems. you changed the HL/TL/FP harness did that work? I appreciate any advice any one has.

I'm doing a 97 2.3L to 4.0L swap. stone02 you seem to be doing the same thing. I have been paying attention to your problems. you changed the HL/TL/FP harness did that work? I appreciate any advice any one has.

that's the same thing i did on my 93. i'm pretty sure we did the entire harness in it.

are there any other module that need to be changed when going to the 4L? computer is a given electric= harness and computer anything else?

Hey guys,
I have a 95 Ranger 4x4 with a 3.0L and I took it out through some water and it ended up hydrolocking and I think it broke a connecting rod or something, but anyway it needs to be replaced. Fortunately I have full access to a complete, running 94 Explorer 4.0L 4x4. I'm going to do the swap and I've been doing some reading so I'm prepared to do a lot of wire swapping and splicing.

The thing that really worries me is that my truck is OBD2 and the expo is OBD1 and I've heard the iginitions are completely different and I know the dash setup is different. How much trouble is this difference going to cause me? is it worth it or should I look for a newer parts truck? Sorry for this being so long winded but pretty much all the info I could find on here was based on 94 and older trucks. Thanks in advance for the help and I'll try to post pics as I go, and btw I'll be doing a 3 inch body lift along with the engine swap to allow some extra room for the 31s I have on.

88rangerv8

I have a 98 Ranger witha 2.5L 5 speed, and I came across a friends dad who is selling a OHV 4.0L w/ the automatic transmission, out of his 99 Ranger for 800 bucks. I know this is a steal. It was said to have about 80k miles, and was babied. This guy is an engineer and now has a 427 in his 99 Ranger. Anyway I have a few questions.

Right now the 4.0L has no power steering pump and no alternator... All the bracketry is still on the 4.0L, however the main accessory components must have went back in the 99 ranger and were made work with the 427.

Anyway 1st question is: Will the power steering pump and alternator off of my 2.5L bolt in to the 4.0L bracketry?

Both Alternator and P.S. Pump looked very similar in the way they bolt up, so i ran the numbers and everything seems to match up. However it was stated in the 4.0L FAQ that no parts will work. Anyone know any differently? Will I need to aquire any differeent alternator wiring for the 4.0L, or different power steering pressure and return hoses?

Secondly, My 98 2.5L has a 5 speed behind it, that means big hole in flloor once automatic goes in. I really dont want to get an automatic transmission column unless I have to. Could a Floorshifter be used? If so, any one in particular? I like the idea of a floor shifter.

Lastly, I want to verify everything that needs to be swapped out and upgraded for the 4.0 to perform the way it should.

So far the only other things I can think of off hand is:
Im sure of: 4.0L EEC(I belive guy w/ the 4.0L still has it), V6 Radiator, Radiator hoses, 8.8 Rearend...

I'm Questionable about: Alternator wiring? Power Steering Pressure and Return Hoses? Driveshaft? Throttle Cable? Other engine wiring? Tons of vacuum lines? Emissions hoses and what not? Transmission floor shifter?

Is there anything else that i am totally missing? Any thoughts or tips on my swap. I would appreciate any in dept knowledge concerning my topic. Any help would be greatly aprreciated.

Thanks,
Chris
I'm gonna go out on a limb here and say that Ford didn't go to the trouble and expense of using different alternator wiring, power steering pump and other items for the 2.3/5 and 4.0. The wiring and vacuum lines will be different for the 4.0 engine.

I would think that you ould use a floor shifter from a Mustang (lever might be a bit short) or something like that. Did the 2 door Explorer Sport have a floor shifter auto?

Mike

we are in the process of swapping a 4.0 from a 02 4x4 in to a 95 2wd that came with a 2.3

what problems am i going to run into with the pats system, can i use my m50d on the 4.0 and if not can i take the transfer case off of the 4.0's m50d and put the tail shaft off of the 2.3's m50d on it

any help would be greatly appreciated

we are in the process of swapping a 4.0 from a 02 4x4 in to a 95 2wd that came with a 2.3

what problems am i going to run into with the pats system, can i use my m50d on the 4.0 and if not can i take the transfer case off of the 4.0's m50d and put the tail shaft off of the 2.3's m50d on it

any help would be greatly appreciated

I'm sorry, but my last post was the outer limits of my knowledge. If the Trans is the same model number, then the tailshafts should interchange, except for the need to take the trans apart enough to exchange the actual output shaft. My last experience w/ auto trans was decades ago w/ a C-3 (and that didn't turn out happy). If you have the shop manual and it's not too complex, you might be able to make that exchange.

I'm still having issues w/ my 4.0 4X4 not wanting to shift to 4wd and 4wd low. THe dealer's tech thinks it's most likely the position sensor on the electronic shift motor, available for $82. Of course, that is a bargain compared to the $401 they want for the whole shift motor assy.

Of course, I could just buy the Cardon shift motor assy for $90 and be done w/ it. I'm gonna try the $32 switch first tho.

Mike

getting ready to swap my 94 ranger 3.0 to a 99 4.0. I have the tranny out of he 99 and also the engine wiring harness. From what i have read the 99 is an obd2 and the 94 a 1. Since it appears that i should have picked up the harness back to the fuel pump as well is it possible to change the existing fuel pump to a unit a wire to a switch? How about the dash from the 94, is there going to be any problems with connecting to the 99 engine?

You are definitely going to have some issues with the interface between the under hood harnesses and the dash harnesses, as the connection between the 2 is totally different.

The 94 harness uses a large round connector to connect between the dash & the engine. It has something like 50 or 60 pins on it.

The 99 Harness uses 3 large square connectors between the dash & the engine, which I want to say total, between the 3, have close to 100 pins.

Your best option, would probably be to take the large round connector from your 94 engine harness, and carefully dissect the end of the 99 harness, and splice it into the round connector off of the 94 harness.

However, Im not 100% positive that this will work. My suggestion would be to get a 94 Electrical & Vacuum Troubleshooting Manual, as well as one for a 99. I have an EVTM for my Ranger that I used when swapping my 1990 4.0 into my 1989 Ranger, and the information that it provided was invaluable.

For what you are wanting to do, having both of those manuals would help you greatly, when trying to figure out the wiring.

Thank you for the reply. Looks like i may be getting into something bigger than i thought. I may have to rethink my decision and maybe just rebuild the 3.0 engine and tranny.

My suggestion would be to find a 94 wiring harness & computer. The engine should work fine, might have a couple differences such as the alternator & such, but for the most part it should be the same.

There is a knock sensor & a cam position sensor on the 99, that might or might not be on a 94, if they arent on the 94, then you just wouldnt worry about them, you'd just not worry about plugging up into them w/ anything.

So i should look for a 94 4.0 wiring harness, right. What is the difference between the 3.0 and 4.0 harness, just curious. What other year truck would be compatable?
And i am going with the swap, just looks like it will take a little longer. The 99 4.0 engine looks pretty good. I have to pick up an engine stand tomorrow and attach the engine so i can start tearing it down. Any suggestions on what i should change? I was going to send the heads out. Should i change the exhaust manifold to headers? If i install the headers before i drop the engine in will it fit without claranc problems?

found a 94 ranger with a 4.0 and manual tranny. Looks like i can take the parts off this and start the swap finally.

Reading these posts bothers me a little.
My 2000 exploder, my brothers 99 exploder and my cousins 2001 ranger are all x code(4.0l ohv) engines and look pretty much alike, are you telling me the exploders are not factory?

the 99 & 2000 Explorers both can have the OHV. 98-2000 Explorers could have either the OHV or the SOHC as both were an option. However, the 2001 Ranger will have the SOHC w/o a doubt. The OHV was not available at all in 2001, only the SOHC.

HI
I have a 88 ranger with a 1991 4.0 v6

Will the headers made for a 1997 ranger fit my stock y pipe?

I do not want to replace the y pipe, I modified it where the cat used to be so I need headers that will fit my stock pipe.

thx

At some point they rotated the mating flanges on the y pipe, but I dont know when. I think they rotated it about 45° so it wont line up w/ previous years. But for the life of me I dont know when they did it.