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?

I thought guys use to swap out the 94/95 pcm for the foxbody pcm like the 89/93 models for the ease of tunabilty ects?I could be wrong,only going by what i sorta remember reading back in the day.:confused:

I kinda remember the same thing - some programming issues with the 94/95. Maybe talk to a tuner who has some experience with mustangs.

I am in the middle of a similar project with my 15 year old son, except I stayed with the V6(4.2 splitport). He was starting to get bored with cleaning parts, but once things started to go back together he started to perk up, and the ear to ear grin when we started the car was priceless. Now I am hoping the weather will cooperate so we can sand, body work and paint by spring.

Weather aern't helping things here either! lol .... Too cold for the kids I guess!

I bet :bleh:.It's freakin cold here,so i could imagine up north from here.

Hey everyone,

So tomorrow is the big day. Tomorrow is the day we pull the V6 out of my daughers Mustang. I've refered to my trusty Haynes Manual and its all coming back to me. It should be pretty straight forward. My daughter is more excited about pulling the motor than I am.

Well, I'll let you guys know how it goes and I'll do my best to take a few pics of the "surgery".

On a side note, anybody want a 3.8L (I'm keeping the intake). I don't think any mods have been done to it. It ran excellent and only had 120,000 km on it. I'm just looking to get it out of the garage once its out. Let me know.

Wish us luck. :tup

Wow ... that was fast. Engine is already sold. And I got full asking price (free).

So confused??? We were about to get started ... even had the hoist set up and she wants to keep the 6 .... huh? Really? Ummm ok. So I guess were keeping the 6 (for now) .. lol ... but 145 HP just isn't going to cut it. I mean, the thing doesn't even really pull on the highway. I have no idea how she is going to pass someone on the 400. So, sadly ... this thread is essentially coming to an end (for now). Like Crafty, I'm gonna start a new thread .... a V6 build thread ... this might still work. With a Stage 3 kit from Supersixmotorsports (I hear the V6 guys rave about) and maybe a Procharger Supercharger some 3.77 gears and a proper tune... we can get this V6 up to a respectable 350 - 400 HP (and I still get quality time in with my best girl). I let you know how it goes. Wish me luck ..... AGAIN.

M90 ?

nothing wrong with going to a sixxer lol as for the stage three kit.:tup:tup but heck, maybe even look into an M112 blower, or turbo? but first thing i'd recomend would be doing the split port swap. (my engine is up for sale, hint hint :wink: ) lol just my 2 cents:wiggle:

if you want to be stuck at 250hp max...:suicide: lol srry not trying to be rude. just i think the M90 is only good for looks. you get the same gains if not better from a splitport swap.

^^^ yeah but the M90 looks WAAYYYYYY cooler LOL oh and theres also Tom Marana racing that specialises in V6 mustangs and there located in Canada

3.8 to 5.0 swap
 

I recently swaped my 98 3.8l to a 5.0 from a 95 just for the fact that there is many more bolt on apps for a 302 i did it in a weekend wasnt easy at all and when i say weekend i meen roughly 18 hours non stop...

here is what i did
PARTS:
Motor from a 95 5.0
ECU from same car
Wiring harness from ECU to engine Compartment( runs under passenger fender)
Smog Contols for the 95 motor Placed them in the passenger fender as well
I had to get a new K frame as well ford used two difernt k frames from 94 to 95 so this may be a part youll need
throttle cable cruise cable
mass air tube
new fuel lines( i chose braided)
certian things just wont fit because they aint long enough
if you just want a running 5.0 in your newer stang this as all you really need but the parts list poosted previously is definitely a great idea especialy while the motor is out of the car

Good to hear you're keeping the 6..

I run Tom Morana Stage 3+ heads, "B" grind cam, roller rockers, Steeda underdrive pulleys, Windstar Upper Intake and I'm putting out 255hp at the rear wheels...the tune still needs a bit of work as we're having issues with check engine lights/car running lean..waiting on SCT to give advice on how to fix the issue as my tuning guy is not able to tune this out

I need help will a 94 3.8 meet emmision /e-test in ontario with a 94/95 5.0?

^^^ wow, talk about bringing a thread back to life.

It should pass emissions - as long as all of your emissions equipment was re-installed after the swap. Unfortunately, as a 5.0 was offered in 94/95 you cant take your emissions test under the Hot Rod category (almost a guarenteed pass).

Would love to see pictures of your project!

thanks VAEM, I look forward to following this thread ,, hey ya never know right ,I may take a second look at my 3.8 lol

^^^ :tup Thanks V6RAGTOP! Actually, if you want to follow our 3.8L V6 build, here is the thread:

https://www.cmoc.ca/forums/t13633/

(I started a new thread as it was no longer a 3.8 to 5.0 build)