4.6 to 5.4 swap? BILL....HELP!!!

[CageFighter_Dan]

That's exactly how I am driving mine every day right now with the original 4.6 pcm while I have the 5.4 engine swapped and installed, so far all I notice is more power that's for sure, idle is just a little rough due to the 4.6 using size 19 injectors and the 5.4 uses size 24 injectors
It is still very drivable! As well my shift points between 40 km and 50 km is a little chopping and bogs same as 80 to 103 km all of this will be remedied when I get the tuner with the custom pcm flash that bill is making for me, will be here monday, trust me! Use the original 4.6 pcm computer and u will be able to use it as a daily driver while waiting for your gryphon from bill or start the order process now, it will be the same set up exactly as mine

[RobbyMartin]

Bill, I'll get you those numbers as soon as I find out what ECM he decides to use. Any other advice from you or Dan at this point? I can't tell you guys how grateful I am for your help.

[CageFighter_Dan]

well from the sounds of things so far my only advice is don't let your mechanic make these disisions for you anymore, you have to tell him you want to use your original ecm/pcm which ever that was in the truck when you brought it to him, and that you will get any and all tuning needs addressed by bill with yout gryphon, all he should be doing at this point is the wrench work i would suggest as soon as you hear it fire up , drive it QUICKLY out of this guys garage before he starts attempting anything else that may affect the drivability issues before you get the tuner installed , best of luck , as for bill all he needed from me was the pcm/ecm which ever lol number that he told you about earlier from your existing hardware that was in the vehicle as well as a list of any other mods you have done past stock stage with this vehicle , ie, change of muffler diameter pipe, removal of the cats that sort of thing and the year and size of the newly swapped engineor as well the original tranny if you haven't changed it , unless it is in bad shape i would leave your original tranny alone as well, the tunes will fix any shifting point issues and torque conversion.

good luck, feel free to pm directly if you have any other issues, all these replies to posts and pms go directly to my blackberry and i uselly just respond via the cell phone as i was doing today with these ones from my job site
benifits of being the boss lol

[RobbyMartin]

Dan or Bill
Would the original 4.6 wire harness plug right into the older 5.4 engine and components? Are all the connectors/pins the same on the 2002 4.6 as the 1997 5.4?
I made the demand that he use the original harness and pcm and he said that the wire harness is different and wouldn't plug into the engine.

[CageFighter_Dan]

there is no reason that he can not use the original harness, i believe your original motor utilized a cop ignition , what ever ignition system that went to your original spark plugs , just use that same system and plug them right into the spark plugs the same way, your pcm will fire it just like it was the original , there is just a difference in size of the injectors is all , but that only gets addressed when it comes time for the tuning, bills side of things, there is going to be some lengthening of some of the wires, such as the one that goes to the back of the throttle body , its really not that big of an issue, and a little bit of modding for the bracket system for which ever ignition system you use. but you might get lucky and not have to , non of this stuff is extremely difficult , and all of the vacuum lines will work the same , if he can't make the original wire harness work , then you have more issues then him being able to finish this job efficiently , i am in no way more then a back yard mechanic and this was my very first engine swap , let alone an conversion, and i managed to do this , so if this mechanic has any sort of papers backing him up or experience he should easily be able to tackle this project. read over my notes i listed before about my personal experience on my swap, as well the connection to the inside under the throttle body sensor ( not sure what it is called) but it comes out in the back from under the throttle body, had a different end on it apposed to what was on my original engine, same sensor, same function just different connection, i simply cut and spliced what i had from the original engine , only two wires to deal with, so the new engines sensor would plug into the original harness, you may not run into this problem , but i think you may. again there is no reason to not use the original pcm/ecm or harness to feed info to it. it does require alittle bit of moddification , but what custom conversion project these days doesn't

[Power Hungry]

Like Dan said, everything should line up pretty well with the original 4.6L harness. Once we know what calibration we're dealing with, we'll be able to better advise on just what tuning changes will be necessary.

Good luck.

[CageFighter_Dan]

i think bill is becoming a little dislexic with the late hours of work lol

pretty sure he ment original 4.6, not 6.4 lol

just had to throw that out there lol

[RobbyMartin]

Originally Posted by Power Hungry

Like Dan said, everything should line up pretty well with the original 6.4L harness. Once we know what calibration we're dealing with, we'll be able to better advise on just what tuning changes will be necessary.

Good luck.

Bill,
The original 4.6 harness is back in the truck along with the PCM, which has the code: GKW3 and part #: 2L3A-12A650-GD

There were literally 3 other PCM's that he tried to get to work and I have their numbers too.

I don't know if you looked at the link with specs of the engines from years '97-'01, but this mechanic seems to think that the differences in HP/TQ on the stock engines from those years are solely from tuning and nothing else. Is there any truth to that? He tried to promise me that all these engines produced the same HP/TQ and the differences come from the factory tune.

[RobbyMartin]

Bill,
According to the link below, the '97 5.4 engine produces 235 HP @ 4250 RPM & 335 ft-lbs torque @ 3000RPM. The 2001 4.6 engine produces slightly less....231 HP @ 4750 RPM & 293 ft-lbs torque @ 3500 RPM. I don't know engines but it seems like the older 5.4 isn't much better than the 2001 4.6. Can the 5.4 be tuned to be closer to the numbers of the 2001 5.4 (260hp @ 4500 RPM/350tq @ 2500 RPM)? I feel like I got screwed with this mechanic/engine swap and feel even more screwed with the engine specs. I am hoping for some piece of mind with the numbers.
Thanks and God Bless

http://www.fordf150.net/specs/engines.php

[CageFighter_Dan]

i can kind of agree with you in the matter of feeling screwed by your mechanic, i have no idea why he wouldn't have tracked down a 2003 or at least a 2000 -2003 5.4 engine, everything newer used alot more forged steel parts i forget which ones but they did make a huge difference in effetiency, some thing about cranks and cams if i remember correctly, i got my 2003 5.4 for only 970 bucks canadian and it was not hard to find from a repitable engine distributor. not to be the barer of bad news but i think this mechanic bit off much more then he could chew or was remotely ready to tackle with his personal experience of what was needed for the project and what would benifit the consumer, being you. in the long run