4.0 Swap

[slclogston]

So, I've been given a little gift from a kind friend......a 4.0 V6 with tranny and transfer case and computer from a 1992 Explorer. And its still running great, the guy who had it before just tore up the front axle putting it into a ditch.
This is going to be my winter project, but after I've read through both the engine swaps in the tech library I still have a few questions.
1) Do I need to get a different fuel pump going from a 2.9 to a 4.0?

Really that's it for now.

 

[klogtruck]

i used the pump out of the ex. just put on my sending unit

 

[mjonesjr]

With you having a '90 BII, you wont need any new fuel pumps or the fuel pumps out of the Explorer.

The '86-'90 BII's have the same fuel pressure at the fuel rail as the 4.0's.

 

[twoll86]

if you have a 90 unless im wrong it could be a weekend project its plug and play

 

[04sd]

if you have a 90 unless im wrong it could be a weekend project its plug and play

Not quite but close. There are still a few wires that need to be swapped. Get a wiring diagram for both and compare. I used a '91 engine in my '90 and it wasn't 100% plug n play.

 

[MikeWild]

my 91 2.9 to a 91 4.0 was plug & play. Pretty straight forward. Never had to change the fuel pump either.

 

[BlackBII]

My 90 to 90 was 100% plug and play, minus the wipers....:icon_confused:

 

[xdjones1]

i actually just did mine about two weeks ago and it was 94 to 90 and it was all plug n play but, i took the computer, all wireing, and dash. the fuel pump, inertia switch, and sending unit are from the 2.9 and i havent had any problems yet.... we'll wait and see

 

[Linux_Geek]

I went from '86 2.9 to 92 4.0 and it was a very easy swap, but definitely NOT p&p. It sure woke the ol' Ranger up though.

 

[slclogston]

Alright, got the engine ready for the taking today and man oh man, I nearly passed out when I saw how similar the two engines are. I mean, this is gonnabe a piece of cake, the hardest part is going to be rebuilding the engine. It runs good, but it could use it and I don't want any trouble with this for a while.
My next question is for those who have done the swap already.
How's your fuel mileage now with the 4 litre? From what I can tell, it might actually be better than the 2.9. And is that fuel tank in the explorer a 23 gallon also? I'm not aiming for a rock crawler here, I just want a good day to day driver that I can take on trails and not worry about it. Also, the last blizzard we had up here had me pulling alot of people out of snow banks and it would be great to have a stronger engine to do this type of work.

 

[twoll86]

from what ive heard and figured from reading the explorer weighs ALLOT more and got about the same mileage so if you can keep you foot out of it you should get mid 20's depending on how you drive it, gearing and tire sizes

 

[trail B2]

i'm doing one right now it is not plug and play but its going from auto to manual adding air conditioning and changing dashes a lot of the plugs you can't change pins because there a different style kept old steering column.

 

[AllanD]

Not too long ago I helped a guy who had already physically
installed a 4.0 into his 1991 Ranger and just needed help with the wiring.

Getting the 2.9 harness out and the 4.0 harness in took all of 75minutes
taking the old harness out to putting the new harness in and actually
starting the engine.

Of course it was a ranger>ranger harness swap....

the Ranger harness is a direct plug&Play into a bronco2, an explorer harness isn't.

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[twoll86]

actually you have a whole truck just swap the dash and put your gauge cluster in it what im doin in my 89