SN95 3.8L to 5.0L Engine Swap
 

OK ... So here I go again ... I'm planning on doing ANOTHER 3.8L to 5.0L engine swap ... this time into a 1998 Mustang. I've already done a clean swap into a 1997 Mustang and I'm VERY happy with it. It looks and runs like it came 5.0 from the factory. I'm so happy with it that apparently I want another one. :) (Truth be told I had a LOT of fun building mine with my dad and so I'm building another one with my daughter - for her to enjoy).

I know there are quite a few people interested in doing a 3.8L to 5.0L swap so I'm gonna do this one online with CMOC, so that people who have no clue what their up against might have a better idea after this. This clearly isn't meant to be the all incompassing "How To" guide - I'm not perfect and don't claim to be and peoples required parts will change quite a bit based on their desired setup, aftermarket parts purchases, and future power adders. Hopefully this thread just gives people a better idea of whats involved and hopefully helps somebody considering the swap, now or in the future.

I've done the swap before, but I'm still wrapping my mind around everything that will be required to make this swap perfect. For this thread, I'll start with the parts list ... this is pretty much everything that was included in the last swap. Here goes (big breath) .....

- Complete engine harness to computer (two harnesses, one side that runs along the passenger side and the harness for the engine)
- Computer (specific to 5 speed or Automatic)
- Alternator harness (or re-use the v6 one, but you will have to cut and extend the wires)
- Transmission harness (specific to 5 speed or Automatic)
- 02 sensor harness
- CCRM (constant control relay module) from a v8 car
- Insutrument Gauges from a '95 GT
- Complete 302 engine or crate engine (should have made this # 1)
- 94-95 Upper intake
- 94-95 timing belt & timing chain
- 94-95 timing cover
- 94-95 water pump
- 94-95 distributer
- V8 cruise control cables (V6 cruise control servo is ok to reuse)
- Spark plug wires and injectors (get all 8 so you have a balanced set)
- 94-95 accesory brackets
- 94-95 motor mounts
- 94-95 headers
- V-8 Fan speed control module
- H-pipe stock or aftermarket highflow 2.5 inch unit
- Catback
- A/C plumbing if you want to keep the AC in the car, don't forget the compressor as well.
- 94-95 induction tube or a cold air kit.
- Smog pump system if you want to keep the smog/egr stuff on the car
- Throttle cable if you decide on a foxbody throttle body setup instead of the 94-95 elbow, you will need an 86-93 5.0L throttle cable and bracket, as well as cruise control cable if the car is equipped.
- Serp belt belt length will depend on accessories installed. There is a diagram out there (I have one on my computer), on what belt lengths to use with whichever accessories are on the car.
- Upper radiator hose I went with the Goodyear blue hose kit..upper, lower, and the 4 small hoses (to heater core, water pump etc)
- 94-95 02's
- 94-95 EGR and sensor or foxbody style if you decide on going the foxbody 5.0L inlet route
- TFI (Ignition control) module
- TAB, TAD, EVR (3 emmissions things in fender) I know a cpl of the V6 ones can be reused
- GT bellhousing Yes or one of those aftermarket steel bellhousings or your tranny wont lineup
- New flywheel and clutch...V8 uses 10.5 inch flyweel and clutch...V6 uses 11inch - make sure its for a 50oz balance and has 157 teeth.
- V8 springs or get some lowering springs.
- Flywheel bolts....different thinkness of flywheel stock 5.0L flywheel bolts or go with ARP
- Secondary A.I.R - the tube that runs from the engine bay down to the catalytic converter
- V8 power steerting lines I changed the pressure hose only {pump to rack}, but it looks like the v6 one could have been re-used
- V8 powersteering pump
- AIR system check valves (x 2) from FORD
- carbon canister and V8 vacuum lines I reused the v6 charcoal canister
- molded hoses for the AIR system .
- K Member will be needed for post '95 V-6's - many aftermarket tubular K-members wont allow you to use the stock spring setup = coil-overs. Only one that I know does is the QA1 K-member.

If you will be upgrading your new 5.0 later, I would also recommend:

- 94-95 fuel hoses from the frame rail to the engine fuel rails.
- fuel pump and don't forget a new filler neck seal while you are there.
- 8.8 rear end

So ..... I think thats it. I can't think of anything else and the notes I took the last time my dad and I did the swap don't mention anything else.

I'm going to be buying as many of these parts as I can new from Ford Racing and the rest aftermarket or from a salvage yard (for those trully hard to find parts). You can save WAAAAAAY more money by buying a donar car or buying everything you need from a salvage yard. It just comes down to personal preferance.

There is an article on the 3.8 to 5.0 swap written by 5.0 Mustang & Superfords Magazing. Here's the link: V-8 Engine Swap - 5.0 Mustang & Super Fords Magazine Its not very detailed - just gives you an overview of the swap and the needed hope that the swap is indeed possible.

If I've missed anything in my parts list please let me know. I'm off part hunting and will be back, hopefully sooner rather than later, with pics and info on how the swap is coming along. Hopefully I'll be able to wrangle some of you into helping me out ... I'm looking at you 1LOW03GT! :)

One more thing ... I already know it is far cheaper to just buy a used V8 Mustang. I'm personally doing this to spend some quality time with my daughter building something that I know she'll enjoy for many years - and hopefully take better care of having spent so much time creating. So please avoid the posts (and they will come) saying "Why don't you just buy a V8?"

Any problems with your insurance company? I had a buddy that was thinking about changing up some stuff, tried to do the right thing and notify his insurance company, and they basically told him the only reason he was changing things up was to race the car.

He got pissed, asked how would they know the difference, and they came back with the fact that they wouldn't, but if something happened and the car was found to be different than the one they insured, they had the right to deny coverage because it was fraud.

Good stuff or what?

I didn't have any problems with my insurance company with the last swap so fingers crossed. Insurance companies are wierd though, I had to find new house insurance a few years ago after we bought a Golden Retriever! The company I was with at the time wouldnt insure home owners with dogs.

Ha ha ha ha -- I've heard Golden Retrievers like to play with matches, so it's no wonder they wouldn't cover you.

Back on topic -props on the list man - would have taken me hours to type all that out , and I hope your daughter appreciates what the old man is doing for her. I woulda loved doing a project like that, and to get a Mustang out of the deal at the end? Sweet.:tup

WOW I had no idea u needed that much stuff.........I was maybe thinking instead of building my 6er this summer i could just swap it with a 351 for the same price......

Thanks man ... I appreciate it. Hopefully she stays the course and actually finishes with me and doesn't get bored half way through. lol ... Guess it'll just take longer if she does!

Yea ..... the list looks intimidating at first. Thankfully, theres a lot of small inexpensive parts in there so it not tooo hard on the pocket book. I've heard you can pick up all that parts you need second hand for under 3000 bucks - less than the cost of a supercharger for your 3.8 and with the 5.0L you'll still have plenty of engine to upgrade - just my take.

That is awesome.Great way to have quality time together,and a good learning expirience for her aswell.She will definitely have a different kind've respect for her ride as opposed to buying one done.
Make sure to keep the updates going.

LOL ... ok, so it's been about 24 hours and I need some advise already.

I ordered the following computer and engine wiring harness for my swap: Ford - 5.0L Efi Engine And Computer Harness Kit ***Limited Supply*** by Ford Racing at LRS - Same Day Shipping!. It was the one recommended in the 3.8L to 5.0L engine swap article I posted above.

Would you guys recommend I go for the A9L computer brand new (Mustang - 89-93 A9l Computer (Pcm), 5.0L Mass Air, Manual Transmission at LRS - Same Day Shipping!) from a '93 Mustang or a TM40 computer from a '95 Mustang used at a wreckers?

I know both computers have there ups and downs. The article I mentioned does not recommend either computer - it actually doesn't specify which one to get. Think it's better to keep the computer designed for this harness? Will either of them function the same in the swap? What do you guys think?