5.4 EFI Engine Trans swap into a 1972 4x4 F-250

[Worldsworstfish]

I want to throw a modern 5.4 EFI DOHC transmission and transfer case out of a 2000 or newer Ford pickup into a 1972 Ford F250 4x4. Has anyone have some experience with this or links to a site where someone has done this. It is going to be frame off restoration,  trying to find any information at all. Thanks!

[averagef250]

It's not the most popular swap because those engines are physically huge and not very powerful or efficient. The factory wiring manuals for the donor drivetrain are the best way to go for anything like this.

[Worldsworstfish]

What other modern motor transmission are others using then?  As far as power, the stock 360 that is in it put out 200 HP in the good days, the 5.4 is putting out 350 HP.  I have an opportunity to buy a  wrecked 2wd Lincoln Navigator that would be the donor engine and transmission, will be able to use the harness from that vehicle.  My measurements, keep in mind not really exact, show that this setup should fit in length and width almost identical to the stock motor am I wrong?

[averagef250]

I own diesel vehicles for a few different reasons, but we did have a couple Expeditions, one with a 5.4 and one with a 4BT Cummins installed in it. The record setting best mileage the 5.4 Expedition got was 14 with the cruise on 55 on an 80 degree day, perfect conditions for 25+ MPG in any sort of halfway efficient engine. A reasonably well tuned and upgrade FE would have got 15+ for the same driving. Virtually the same exact vehicle powered by a 250HP 3.9 Cummins, but packed with 3 teenagers, pregnant wife, one wheelchair and a weeks worth of accesories, about 7000 pounds total, netted a 24 MPG return driving 75-80 on the flats and slowing down before every mountain to run 3/4 throttle or so up every grade through the Siskyous for 600 miles.

In terms of wow factor the FE is likely more impressive to most people than a 5.4 Triton. I don't think the Triton motors will go down in history for accomplishing anything great. I mean seriously, the GM LS1 motors get far better mileage make WAY more power than the Triton stuff much cheaper and they have PUSHRODS and ONE camshaft. Makes no sense? I really dislike GM products, but would actually take a GM 5.3 or 6.0 over a Triton motor.

I've swapped three EFI 300's into these trucks. They're a nice motor, but not quite a direct inject turbo diesel.

I think it would be real fun to put one of those new Ford turbocharged V6's from an F-150 into an older car or light pickup.

I dunno, I actually do this stuff for a living and get these questions a lot. I also get to hear a lot of peoples frustrations with their swaps and disappointments too. I get to finish work other people start from time to time too.

Overall, I'd say go out of your way to keep it reasonably uncomplicated- Do things the KISS route when possible. The 5.9 Cummins swaps are pretty well proven, there really isn't much guesswork if you start off with a realistic plan and budget. You can't beat the value you get buying a 90's Dodge 5.9 with an NV4500 or auto for around $3000. Just something to think about. I know diesel isn't for everyone and one persons ideas of what's cool are totally different from anothers.

[elgemcdlf]

I have not done it but it seems to becoming a more & more popular swap with earlier trucks. I am a fan for updating. I do not know specifics of the Triton but a 5.4 sure looks impressive under the hood of an old truck. I almost did a V10 swap into my truck until I found out it had less displacement than my 460. I like the looks of the modern engine under the hood of an old truck if done well. All depends on what you are looking for but I would think the WOW factor would be high when the hood is opened.

[Ranchero50]

I would honestly wait and find one of the new 5.0's or an ecoboost to swap in if you are determined to go modular.  I'm not sure what Ford is doing for security but I heard you need to run the stand alone controller for the 5.0...

Dad's '03 F250 with the 5.4 gets a whopping 15mpg.  It's parked in favor of mom's old Camry now...

The wife's '03 Explorer 4.6 AWD might get 13mpg if I'd drive it at speed far enough.  As is it's just a around town crawler.

[JG F100]

I'd like to see someone do a 6.2L swap, they are in the raptors and the highend f150s. Being they are also in the superdutys, maybe more people will think about them. I did a quick search the other day and saw some on ebay for about $4k. Problem is aftermarker support for the ecu. I've seen standalones for the new 5.0L but nothing for the 6.2L or ecoboost.

[Worldsworstfish]

Average,  I did the Cummins in a 79 F250.  Stroked a 69 F350 4x4 and did the 5.0 in a 34 Dodge.  

Was looking for something different, but with some requirements.  My dad bought this 72 new and then gave it to me when he bought a new truck in the 90's.  I want to completely restore and update and give it to him for his 70th birthday.  I want to go to the automatic, and A/C, however he hates diesels so that option is out.  I will start tearing it down to the frame on Monday.  Have a couple concerns with swapping to the auto, the first being length of the transmission, haven't got to measuring things yet.  Will be doing that Tuesday when I finish pulling the cab.  I know I gotta leave a decent driveline between transmission and the transfer case but have toyed with idea of looking at using a modern transfer case if possible.  As far the the theft deterrent goes, going to go all out on this one, that includes fabbing up the dash putting the modern dash, right down to the ignition key.  I have been looking for a 5.8 also however not as plentiful as the 5.4 so that is why my first reaction was to go with the 5.4.  

Still looking for any other options or ideas anyone may have.  Appreciate the response, first time I tried this forum stuff, posted on another site and no response at all there so appreciate any suggestions or why don't you remove your head from there comments!

[Ranchero50]

Hmmn, '94 or '95 F250 351w with auto OD / 4x4 case.  Run a mustang puter and wiring harness with MAF, what ever roller cam and roller rockers you want and some decent shorty headers should be a happy combo.

[70 ranger]

I had the same dilemma a few years back and opted for a full body swap using a 95 f150. This opened a whole other can of worms but after a year or so of full time driving i have to say that I am glad I did it this way. I also got power steering, power brakes and anti lock rear brakes. I also am installing a/c when I get around to it (I have all the stuff just no time). Not saying this is the best route to go, just another option.

[averagef250]

If Dad's going to drive it what would he want?

EFI 300's a great option if you don't think he needs tons of power.

I didn't buy my '70 highboy new, but have some seat time in it for sure. I'd be disgusted if it ended up with a disposable plastic dash from a newer vehicle.

[Worldsworstfish]

He will need the power, he pulls a horse trailer, and flatbed with a tractor on it.  

Not going to replace the dash, should have been more specific, will install the gauges into the dash.  Will keep it essentially original for looks.  

The more I look at things the 351 is the direction I am leaning.  

Body Swap, been there, tried that, realized I am not a masochist, returned to original frame.  

However there is a supercharged 5.4 in a wrecked Saleen truck that just showed up at the auction house, all the damage is in the cab and box area went and looked at it today only 38000 miles on the truck so my decision may be made.  Will see at the sale in a couple weeks.  If I can get the wrecked truck for a decent price that is what will go in it.     It will fit if I have to use a shoehorn!

One question has anyone went with CV Driveshaft to connect to the transfer case.  Was wondering if I went this route if I could get away with running a shorter line?  If so how short have you got away with?

[Ranchero50]

I think the most honest answer is the highboy Xfer case isn't very strong or mounted well enough  in the frame for decent amounts of HP.  The Saleen driveline would be a neat swap and should take a regular 4x4 5.4 tranny / xfer case behind it without too much grief.

[averagef250]

Atleast supercharged has a bit of go to go with the bad mileage.

I agree with Jamie on the transfer case/driveline question. Nobody's happy with the divorced transfer case with any sort of power going through it. It just doesn't work right and only gets worse when you shorten the center shaft.

You can bolt a 205 up to a later model gas transmission, they're all 31 spline output with the same 6 bolt flange. The late model transfercases don't fit between the frame rails very well. I guess it comes down to how much cutting you can stomach, but 205's are cheap and one would work fine for what you're planning.

[71fordkid]

just remember, if its too new, it will want to see door ajar status(in the new trucks, this switch is part of the door latch), it will need a pats (passive anti theft system) tranponder key, it will also have abs and things like that intigrated into the pcm. this means that if its left out, you will have an abs light on all the time. if you dont do anything with vehicle security and it has a pats system, it will not start.

there are also alot of different modules in the newer trucks. you have the battery junction box(fuse box under the hood, gives power to many different modules), the sjb (smart junction box, gives power mainly for body functions and systems), pcm, rcm (restraints control module), the insturment cluster is also its own module in the newer trucks. they all work together, and if one isnt working right, none of them will.

Not tring to discourage you, but as someone who works on these every day, this is going to be VERY labor intensive, especially if you want to do it right and have every module working like its supposed to.

However, if you go with a V10 out of say, a 99-01 f250, i believe that the pcm is the only module that has anything to do with the engine.