Engine Swap - '92 5.0EFI/AOD into '66 Ford F100....

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Originally Posted by 34_40

Good to hear your making progress. Pipes came out nice and the tips "make it" a finished job.

Still like the 5.0? Does your carbon can have a vent on it?

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Thanks, Mike! Yeah, I'm lovin' the 5.0 so far. My speedo is off about 10mph. My tires are a little tall (31") for the AOD trans so at 70mph I'm only running 1800rpm, which means at 55, it's only running about 1500rpm. It kinda lugs a little at 55. Whenever I can get around to lowering the truck a little I'll change tire size and correct some of that.

Regarding the charcoal canister, I have a line from the tank connected and the other line the usually goes thru the purge solenoid to the intake just has a roll-over vent stuck in it that came with my tank. Combining Roger's ideas with those of a fella on my Ford truck forum, I think I can use the vacuum purge control valve but need to get a vaccum delay valve and possilby a vacuum check valve so there isn't a continual vacuum drawn on the canister. Bigger fish to fry and the moment but will let you know what I figure out....;)

Glad its all coming together Randy....Pics look good..!

Have you driven it enough yet to get a feel for what the mpg might be Randy? I've got an AOD going in my '71, just wondering what the 302 EFI does?

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Originally Posted by Dave Severson

Have you driven it enough yet to get a feel for what the mpg might be Randy? I've got an AOD going in my '71, just wondering what the 302 EFI does?

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Hey Dave, sorry I missed this post. I have put about 500 miles on the truck since the swap but don't yet have an accurate reading on the mpgs. It's been mostly city driving, the speedo is off 10mph and I still have to drop the tank again to sort out the sending unit issues. I've been keeping the fuel level on the low side in case I have a window of time for dropping the tank. It's no fun to drop it but it's even less fun when full.....:CRY::CRY:

Will let you know as soon as I know....but I'm sure the true benefits of the AOD won't be revealed until I take a little road trip.:3dSMILE:

I dropped the fuel tank again today and finally found the source of my inaccurate gas gauge. The connector on the ground wire that bolts to the sending unit was not squeezed tight enough to make a good enough ground.:CRY: What a PITA!! But I'm glad I found it. After a trip to the gas station, the gauge now shows FULL!! Yay!! We'll see how long it lasts.......:LOL:

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Originally Posted by randyr

The connector on the ground wire that bolts to the sending unit was not squeezed tight enough to make a good enough ground.:CRY: What a PITA!! We'll see how long it lasts.......:LOL:

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(in your best Maxwell Smart voice) AHhhhhh.. the old loose crimped connector trick...:p

In your CA weather.. it should last...... forever!:)

Loose grounds are the WORST! Problem is they're going to show continuity on a meter, but you can't easily tell that there's resistance there and it doesn't take much to mess up an instrument feed. Glad you found it and got it fixed!!

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Originally Posted by rspears

Loose grounds are the WORST! Problem is they're going to show continuity on a meter, but you can't easily tell that there's resistance there and it doesn't take much to mess up an instrument feed. Glad you found it and got it fixed!!

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True, loose grounds are pretty bad but maybe not as bad as worms in your paint....:eek::whacked:

I wired both the fuel pump & sending unit through a 4 pin connector back at the tank so it would be easier to disconnect for tank removal. During this process I also figured out my multi-meter tester had gone bad. :mad: It's hard to diagnose a problem with a defective tool! Once I figured out the sending unit actually works, I had to look more closely at all the connectors. The flaw was subtle but seemed to be the only weak link.

Funny how it doesn't matter how many "do-overs" are required to fix something, it's still kinda rewarding to turn on the key and see it work!! :D:D

So where are the completed pics at man? :LOL: We should be starting on my Mom's 68 Mustang shortly. I'll post a thread here on it. I may be picking your brain since you are driving yours now. Well maybe I guess. :LOL:

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Originally Posted by 40FordDeluxe

So where are the completed pics at man? :LOL: We should be starting on my Mom's 68 Mustang shortly. I'll post a thread here on it. I may be picking your brain since you are driving yours now. Well maybe I guess. :LOL:

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LOL! Sorry, Ryan, I didn't post any more pics cause the looks under the hood haven't changed since post #106. I've put a little over 1200 miles on it so far and love it! The last 2 tanks I've averaged 16mpg with combined city/highway driving. Hoping to move on up to 20 or so on a road trip.:)

Don't remember if I posted this already but I finished running the pipes out the back. JBA shorty headers with 2.5" exhaust with 50 series Flowmasters. Sounds pretty nice.
http://i1027.photobucket.com/albums/...psb87b39d4.jpg

I recently went to the annual F100 Western Nationals. Here's a couple of pics of the truck at the show...
http://i1027.photobucket.com/albums/...psb186bacd.jpg

http://i1027.photobucket.com/albums/...psb5a1a052.jpg

Yes, I'm happy to try to answer your questions and share what I learned. Just give me a shout anytime!:D

MPG has to be one heck of an improvement, Randy!!!! All the frustration of a swap gets forgotten when the results are so good!!

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Originally Posted by Dave Severson

MPG has to be one heck of an improvement, Randy!!!! All the frustration of a swap gets forgotten when the results are so good!!

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Yeah, Dave, so far it looks like I've doubled my mpgs over the 352. Plus, I've sold the old engine, trans, headers, exhaust and nearly covered my initial outlay for the new engine/trans!:3dSMILE::3dSMILE:

It looks very nice Randy! How much gain do you think you actually see from the Explorer type intake? I'm thinking about getting one fot this stang, but not real sure it is a needed piece.

:3dSMILE:

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Originally Posted by 40FordDeluxe

It looks very nice Randy! How much gain do you think you actually see from the Explorer type intake? I'm thinking about getting one fot this stang, but not real sure it is a needed piece.

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Everything I read boasted a 15-25hp increase with the Explorer intake because its flow numbers are about the same as the Mustang Cobra GT40 intake. To maximize the performance gains it would probably be more helpful to pair it with the GT40 or GT40P heads but I didn't have time or money for all that at the moment. The '92 5.0HO is rated a 225hp with stock intake & exhaust. It's anybody's guess as to how much I've increased it with the JBA headers & Explorer intake. It seems to have plenty of power for how I use it....:D

Thanks for the info. Right now funds will determine her engine. I have a different cam, Headman headers, bigger injectors, Ported heads with the correct springs for the cam, and map conversion parts. If the funds are there we will be rebuilding the 302 that we have. It was removed from a 90 or 91 Grand Marquis. I think I'll get the explorer intake as that is a cheap increase compared to an after market one. I got these parts from a buddy who raced his 5.0 but then went to a 331 stroker and carb. He gave me a new fuel pump in our trading too. But now I have to figure out how to put it in the stock tank.

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Originally Posted by 40FordDeluxe

He gave me a new fuel pump in our trading too. But now I have to figure out how to put it in the stock tank.

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Here's a couple of links that will might give you a few ideas on the fuel pump thing....
Page 4 of this article is about an external fuel pump setup on a '66 Mustang EFI Mustangs Plus - Tech Articles - Project EFI GT (Page 1)

Tanks, Inc has a '64-68 Mustang fuel tank for EFI already setup for internal pump. This is the one I put on my truck.1964-68 Ford Mustang Fuel Injection Tank

And here are instructions on how to cut a hole and mount an internal pump yourself. It might be kinda scary on an old tank but.....;)In-Tank Pump Installation

Thanks Randy! We already got a new OE type replacement tank, so I might try the last one.

Just read your whole thread; killer job, Randy!

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Originally Posted by falconvan

Just read your whole thread; killer job, Randy!

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Wow! Falcon, thanks so much!:3dSMILE::3dSMILE:

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Originally Posted by randyr

True, loose grounds are pretty bad but maybe not as bad as worms in your paint....:eek::whacked:

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PAINT??????? We don't need no stinkin' paint.
x
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Originally Posted by techinspector1

PAINT??????? We don't need no stinkin' paint.
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x

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yeah, Tech, it'll be a while before this truck gets new paint. I made that paint comment back when Roger had a caterpillar (or some kinda worm) crawl across his new wet paint....:LOL::LOL:

I'm putting a 89 5.0/5 speed into a 59 fairlane and your thread really looks heplfull, thanks for taking the time to post pictures.

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Originally Posted by 59 fairlaneman

I'm putting a 89 5.0/5 speed into a 59 fairlane and your thread really looks heplfull, thanks for taking the time to post pictures.

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Hey, thanks, Fairlaneman! I hope you start a thread and post up some pics of your process. If you have any questions, please give a shout and I'll be happy to tell you what I've learned.:)

Last week I got a PM from a new member with some questions about my fuel tank swap on this truck so I went back to take a look at the thread...Holy Crap!! It's been over 3 YEARS since I posted any updates...:whacked::whacked:

Well, I've put close to 40K miles on it since this swap and I still love it! When we last talked, I was having some radiator issues...Well, with the help of the awesome guys at Champion, we finally figured out the side flanges on the '65-79 F-series radiators were just wide enough to snug up against the frame rails at the very bottom in such a way that it could no longer "float" on the rubber mounting. The flex frame on the truck and non-flex aluminum radiator came to a major disagreement after about 6 months and would start leaking at the bottom. It took 3 or so radiators for us to figure this out. We trimmed the lower flange on the last new radiator before mounting and it's been great for over a year now. I can't say enough good things about the guys at Champion for sticking with me to figure it out!!! Love those guys!!:D

I now have a nice aluminum shroud with dual fans and no leaks!!! Runs really cool no matter what LA traffic is like...

I've also lowered the truck using DJM 3/4 drop kit...3" front 4" rear. I got some 17" steelies from Wheel Vintiques 17x7 front, 17x9 rear and capped them with some re-pop bottle caps....

Next up is swapping in a 8.8 rearend with disc brakes, 3.55 limited slip from a '93 CrownVic/GranMarquis. I had to trim off most of the CV mounting brackets, weld on new spring pads, shock mounts and adapt this beefy rear sway bar. The CV rear is 64.25" between wheel mounting surfaces, which will work perfectly with my wheels. It also has 5x4.5 bolt pattern, which works for me, too. The stock F100 bolt pattern is 5x5.5. It might have been cool to fab in the 4-link system from the Crown Vic but I didn't have time for all that since this truck is my daily driver. I have to plan my additions and conversions to be able to be completed over the shortest time possible.
I'm also converting to a hydroboost braking system as well. I'll post more pics on that as I move forward...

BTW Mike (34-40), this stuff isn't the "teaser" I gave you a couple of weeks ago...that's still developing....:D:D;)

BTW Mike this stuff isn't the "teaser" I gave you a couple of weeks ago...that's still developing....


Hi R2, the pickup is such a sweet ride! And the coming upgrades will take it a notch higher yet!

I went back and re-read the whole thread and I'm left with a question.. did you ever figure out the carbon canister operation?

I went back thru the thread too......what a neat project.


My favorite part. ".........I've put close to 40K miles on it since this swap...."



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Those of us in the "Anti Nosebleed League" (we bristle at certain pronunciations of our acronym) appreciate the lowering.....................:D

I think that for any rod with power steering-Hydroboost is the way to go----and the one from mustangs is perfect compatability with ford rear ends and disc fronts--

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Originally Posted by Bob Parmenter

Those of us in the "Anti Nosebleed League" (we bristle at certain pronunciations of our acronym) appreciate the lowering.....................:D

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LOL!! I'd like to go down another inch or so but it's kinda hard to do with the twin-i-beam setup....of course, a completely different IFS isn't out of the question but I've got a '37 to finish first!!!:D:D

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Originally Posted by 34_40

BTW Mike this stuff isn't the "teaser" I gave you a couple of weeks ago...that's still developing....


Hi R2, the pickup is such a sweet ride! And the coming upgrades will take it a notch higher yet!

I went back and re-read the whole thread and I'm left with a question.. did you ever figure out the carbon canister operation?

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Hey Mike, thanks for the nice words! I'm going for a notch lower, not higher! Haha!
Actually, I have never revisited the carbon canister issue...seems a shame after Roger posted all that fine art work about it...;);) It's still connected to the fuel tank and has a vent valve on the hose that would normally be cycled back thru the intake. I never smell fuel from it and the EPA lovers still give me lots of compliments on the truck so I guess I'm good for now....:D

Nice photo of the truck . . . and that 4,400 HP GE ES44C4 locomotive sitting next to it.

Randy, the truck looks great! Hopefully in the next year I'll get some time to do the 5.0 swap in my Mom's 68 Mustang.

Jack, 4400hp is all? :LOL: Those things do work. I still somewhat regret not taking the job years back working on them back in Nebraska.

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Originally Posted by 40FordDeluxe

Randy, the truck looks great! Hopefully in the next year I'll get some time to do the 5.0 swap in my Mom's 68 Mustang.

Jack, 4400hp is all? :LOL: Those things do work. I still somewhat regret not taking the job years back working on them back in Nebraska.

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You just need a few more projects, Ryan!!!:LOL::LOL::LOL:

4400hp? I could still take him the quarter! Ha!

I've been doing a few more improvements to my daily driver...I swapped in a disc brake 8.8 rear end from a '92 Grand Marquis with 3.55 gears & limited slip. It might have been fun to utilize the 4 link setup but I didn't have time for all that so I smoothed it out, welded on some spring pads and bolted it up....remember this is my daily driver and solo ride, so all "improvements" must be planned in advance and executed with minimal down time. The Gran Marquis/Crown Vic rear at 64.25" between wheel mounting surfaces was the perfect width for my 17x9 wheels. I already had a Hotchkis 1 1/8 rear sway bar which I adapted to fit the sway bar mounts already on the rearend.
http://i1027.photobucket.com/albums/...psv1l5vvu2.jpg

http://i1027.photobucket.com/albums/...psgglwpvxw.jpg

Now since I have 4 wheel disc brakes I needed to swap to a 4 wheel disc MC. I was never very happy with my power booster so I started researching a hyrdoboost conversion. I got the hydroboost unit from a '95 Astro van, but several vehicles seem to use this same basic unit. I modified the firewall mount and had to shorten the pedal plunger. I got an aluminum Corvette style MC from Speedway and a Wilwood prop valve. I put a "T" in the return hose to the power steering pump. I did some mods to the factory Astro hoses so they would work but I will eventually get some made that fit a little better. So far, the brakes are amazing!!! But like you guys were saying on Seth's thread, the power steering pump is a bit noisier that I prefer....hmmm...
http://i1027.photobucket.com/albums/...pswtk0rvsl.jpg

http://i1027.photobucket.com/albums/...psaswcmpkb.jpg

http://i1027.photobucket.com/albums/...psdvuohejd.jpg

Looking good there Randy. Did you really accomplish all the "upgrades" in a single weekend?

Or was it a couple / few?

Stinkin outfit, how did I never see this thread before. I gotta learn to scroll down the page a little further. Anyhow, glad I seen it now. I got a co worker who is looking at doing this to a 47 Ford Truck. Anyhow, nice work !

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Originally Posted by 34_40

Looking good there Randy. Did you really accomplish all the "upgrades" in a single weekend?

Or was it a couple / few?

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Ha, Mike! Actually, it went in phases....I bought the rearend a few months ago and did all the prep work on it to get it ready to install. About 3 weeks ago I jacked it up and swapped the rearend. That went fairly smoothly and the disc brakes actually worked pretty well with the existing MC/Booster/combination valve, so I drove it for a couple weeks while figuring out the rest of the hydroboost conversion.

The hydroboost conversion had a few snags....I was initially using a hydroboost unit from the PickyourPart, which appeared to be fine, no signs of leaks, etc. I got everything installed/bled/etc and took a couple of spins around the block. Seemed to be working great but no real testing yet....:rolleyes::HMMM::eek: I needed to drive to the Valley Monday evening...I drove about 10 miles in rush hour traffic and the truck was dragging and I started smelling something....I pulled to the shoulder and found power steering fluid pouring out between the MC & hydroboost, plus the radiator was spewing...Yikes!! Thankfully, I have the premium version of AAA. Got a free ride home on a flatbed. :D I replaced leaky hyrdoboost with a freshly rebuilt one and all seems to work great now.

So, I guess the bottom line to your question.... A few! :LOL::LOL::LOL: