Quick '03 3.8 V6 to 4.6 V8 engine swap ... tech advice wanted
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Old July 18th, 2011, 11:13 PM   #1
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Quick '03 3.8 V6 to 4.6 V8 engine swap ... tech advice wanted


Hey guys,

OK... so, now I'm opting for the 4.6 GT engine swap. As per my BAD SOUND thread, this is the direction I'm looking at. Since I am in Canada, cost differences in buying a GT is slightly skewed. Those of you who have seen Sally III and know her issues and have read the other threads may advice a bit better.

So here is where I stand:

I'm making arrangements at 4.6 mustang engines with low mileage. I have someone who has the facility and equipment and necessary experience to do the swap. Given that he does it on GM's but with turbos and superchargers.

I need to know what I'll be missing in the swap and so far this is what I'm seeing to need:
4.6 Engine
Exhaust Manifold (I have custom true dual Mach 1 Take-offs after the cats)
Entire intake assembly
Wire Harnesses (plus extensions)
ECM

It seems that the part numbers for a v6 alternator is different form a GT so let me know if my v6 alt is useable. I'll see if I can get the engine complete with accessories.

From what I know, the GT and coupe transmissions are the same... T56 is what I'm getting from the engine supplier... T5 is what I've read for both.

Rear end and suspnsion can be for later (and BREMBos).

Advice on the build from techies would be appreciated.

A
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Old July 19th, 2011, 01:04 AM   #2
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a T56 is a six speed tranny, used in the cobra mustang. You can get it to work with the 4.6
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Old July 19th, 2011, 02:38 AM   #3
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Sound like you got it down pretty good. although its alot easier with a donor car.

Are you building the motor at all?
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Old July 19th, 2011, 07:50 AM   #4
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I am in Saskatchewan. I got intake parts laying around. Text me. 3062418935
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Old July 19th, 2011, 08:41 AM   #5
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Originally Posted by adryan View Post
It seems that the part numbers for a v6 alternator is different form a GT so let me know if my v6 alt is useable. I'll see if I can get the engine complete with accessories.
Try to get the engine complete with accessories. The V6 accessories are completely different from the V8's.

Originally Posted by adryan View Post
From what I know, the GT and coupe transmissions are the same... T56 is what I'm getting from the engine supplier... T5 is what I've read for both.
The V6 and GT use two different bellhousing boltpatterns (Late Windsor V8 pattern vs. Modular V8 pattern).
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Old July 19th, 2011, 09:18 AM   #6
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Originally Posted by Tcohoe View Post
a T56 is a six speed tranny, used in the cobra mustang. You can get it to work with the 4.6
That's an affirmative. Check out Jazzer's complete how-to T3650 to T56 swap in the 99-04 section. There's lots of little parts required.

However, watch out. A GM or Dodge T56 is NOT the same as a Ford T56. Some people have made that mistake.

I would suggest getting a T45 or T3650 5 speed, they're much cheaper and much more plentiful. I went to the T56 because I'm planning on putting about 550 ft-lbs to the ground, and I'll need the strength.

Also you're aware it's a lot more than just an engine right? You'll likely need the K-frame and brake setup from a GT. The GT used hydroboost brakes, based off the power steering pump. I'm not sure if the V6 PS pump will just bolt up to the V8 FEAD (Front Engine Acessory Drive.) Also make sure the cooling packages are the same for V6 and V8.

...lots of interest in 6 to 8 swaps lately huh? I wonder why.
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Old July 20th, 2011, 08:14 PM   #7
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Thanks a lot guys for your input. It assisted me in finally making the decision I made. It seems like a donor car would be best for the swap. Since I don't have one readily available and the cost/downtime will escalate if I did move forward... I ordered a used A Grade 3.8 with 43K miles this morning and it will arrive tomorow at my engine guy's shop and he'll have it ready for me in 2.5 days. I'll also get him to install a high-performance clutch while it's apart. Check out car-part.com just in case anyone is interested.

Since I still have my other engine, I plan to do a proper and thorough port and polish of my older engine's heads and upper/lower intakes. My machine shop/turbo guy and myself will take care of that. We were actually supposed to do a DYI Windstar swap before this happened so now we'll have a mock-up engine to do the modifications on. I'll see how the newer engine performs first and let it settle for a week or two which gives us about that time to complete both projects.

We were also planning a turbo build during the coming winter. This situation has somewhat changed the options. If budget permits, I'll see if I can rebuild my older engine and get my hands on a 4.2 Stroker kit from moranav6racing.com who is literally 3 minutes away from where I work. I'll also see if he'll hook me up with a turbo setup while we're at it. We'll see.... I've got til winter to decide since she going into storage when the white stuff falls.

It would have been nice to put on a 4.6 but there's too much downtime and too much unknowns. I'm sure my daughter will like like the car no matter what when I hand her the keys next year when she gets her license. Also, it's the only way I can think of to have an excuse to my wife to get the 2012+ 5.0


A
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Old July 21st, 2011, 09:07 AM   #8
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is it too late to order a 4.2 instead?
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Old July 21st, 2011, 08:27 PM   #9
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Originally Posted by Dbovine View Post
is it too late to order a 4.2 instead?
A tad bit late and a hell of a nice shiny penny for now. $2,300 for the kit or $4k installed. I dropped off the car today at my engine guy's shop and I ordered the engine yesterday drom the engine supplier and their free shipping should've arrive today. All this for the fraction of a cost of even just ordering the kit. Since I now have an extra engine to work with, I gotta really think about what I'd like to do. It helps to have a machine shop/turbo friend with all the necessary machines and even a mandrel bending equipment to help out. Right now I'm good with getting that engine hooked on and port and polishing what I can.... VAP windstar is still in the picture but I'll see what's up.

A
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Old July 23rd, 2011, 05:27 PM   #10
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Here she is on the gurney being operated on. They already got the engine out and the intake is in my trunk and will be ported and polished next week. The only problem is... the shop manager did not know that I ordered the engine for delivery on thursday since I was dealing with the owner. He refused to accept delivery and was returned. It took until friday afternoon for me, the shop owner and the engine supplier to figure out what happened. Should be there monday and ready for tuesday (fingers crossed).















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Last edited by adryan; July 23rd, 2011 at 06:03 PM.
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