Block Swap Help! Instruction(s) NEEDED!

[91turbogsx]

Everything from your 02 will bolt to the 97 block. He was just stating small differences in the front cover and such. As long as you swap everything you will have nothing to worry about. There were small revisions over the years on the blocks casting but it doesn't effect the interchangeability of the parts.

 

[juniort444e]

I swapped a 95 into my 01 and here's what i had to change. Some of the parts could have been because of it coming out of a short bus with van front end.

Front covers
Intake plenums.. the bolt patterns are the same, with the older plenums having 2 less bolts. I welded those closed.
Oil pickup tube
Modified inside of oil pan to fit new oil pickup tube
Swapped accessories from mine to it which where on different sides.
Probably missing a thing or two but all the newer stuff will interchange with the older blocks and vica versa.

Oh...and the motor mounts were different. I know it was because of the motor coming out of a can but always something to double check.

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[91turbogsx]

I was trying not to confuse him. He is starting with a 97 short block with what I'm assuming limited parts attached to it. If he literally swaps everything from his 02 like he is saying he should have no issues.

Yes there are differences in different vehicles but essentially the block is the same. I'm trying not to confuse you or make you nervous about tackling the project. Good luck. Any more questions we as a community are always here for ya!

 

[ToMang07]

I swapped a 95 into my 01 and here's what i had to change. Some of the parts could have been because of it coming out of a short bus with van front end.

Front covers
Intake plenums.. the bolt patterns are the same, with the older plenums having 2 less bolts. I welded those closed.
Oil pickup tube
Modified inside of oil pan to fit new oil pickup tube
Swapped accessories from mine to it which where on different sides.
Probably missing a thing or two but all the newer stuff will interchange with the older blocks and vica versa.

Oh...and the motor mounts were different. I know it was because of the motor coming out of a can but always something to double check.

Sent from my DROID RAZR using Tapatalk

That's the second time I have seen reference to a oil pickup tube... more info on this (what exactly needs to be done, a swap over, modification, fabrication, etc) would be much appreciated!

I was trying not to confuse him. He is starting with a 97 short block with what I'm assuming limited parts attached to it. If he literally swaps everything from his 02 like he is saying he should have no issues.

Yes there are differences in different vehicles but essentially the block is the same. I'm trying not to confuse you or make you nervous about tackling the project. Good luck. Any more questions we as a community are always here for ya!

LOL, MUCH appreciated!

The short block might have extra parts, not sure yet, but like said, I'm after the block alone, the rest I just want to swap over. My heads, injectors, manifolds, turbo, everything. :rockon:

And I apreciate the continued responses from everyone!

 

[91turbogsx]

If you use your 02's front cover, oil pickup tube, and oil pan you shouldnt have to do anything else to the tube.

 

[ToMang07]

If you use your 02's front cover, oil pickup tube, and oil pan you shouldnt have to do anything else to the tube.

Ok, Cool beans, thanks

 

[Chvyrkr]

Do yourself a favor and get a set of factory Ford manuals, it will have all the info you mentioned earlier as needing.

As to block compatibility, pay attention to where the oil pickup is. 96 should be in same location as later model, but if its not you need to make sure you have the front cover and pan that matches the pickup. Your later model 02 front cover would be the nest one since it has the cutout at the HPOP gasket for the integral filter gasket, you cannot use that gasket in the earlier covers. There are other differences in the blocks but nothing that will matter for you.

If you are going to swap all your 02 stuff onto the early block make sure you swap the pass side exh manifold, it is different. Other than that Irates kit will replace your pedestal etc.

When I did my forged rod swap I used an E99. Only the drivers side manifold is different. Pretty sure all 7.3's have an identical passenger manifold.

And X2 on using a ford manual. PSN used to have one in their library.

 

[Big Bore]

When I did my forged rod swap I used an E99. Only the drivers side manifold is different. Pretty sure all 7.3's have an identical passenger manifold.

And X2 on using a ford manual. PSN used to have one in their library.

We swapped an E99 into an 02 last year and the manifolds did not need to be swapped. I'm almost positive the passenger side manifold on an OBS motor has to be changed to an E99 or later. Too much crap going through my head lately but I would swear on that one.

OP, your late model engine has a filter in the HPOP reservoir gasket, the cover is different in the gasket mounting area vs the OBS cover to allow for that integral filter in the gasket. Highly recommended. However earlier covers had the oil pickup to the pan on the opposite side, that pickup connects to the front cover. The oil pan was also changed in order to accommodate the new pickup tube location. So, as long as you keep the same years together you should be good.

If you don't want to remove the cover (understandable since it's a considerable amount of work) then don't worry about it. Just remeber to get the HPOP reservoir gasket for the year of the cover, not the truck, using a filter gasket on the early front cover will crack the cover when the bolts are tightened.

 

[ToMang07]

We swapped an E99 into an 02 last year and the manifolds did not need to be swapped. I'm almost positive the passenger side manifold on an OBS motor has to be changed to an E99 or later. Too much crap going through my head lately but I would swear on that one.

OP, your late model engine has a filter in the HPOP reservoir gasket, the cover is different in the gasket mounting area vs the OBS cover to allow for that integral filter in the gasket. Highly recommended. However earlier covers had the oil pickup to the pan on the opposite side, that pickup connects to the front cover. The oil pan was also changed in order to accommodate the new pickup tube location. So, as long as you keep the same years together you should be good.

If you don't want to remove the cover (understandable since it's a considerable amount of work) then don't worry about it. Just remeber to get the HPOP reservoir gasket for the year of the cover, not the truck, using a filter gasket on the early front cover will crack the cover when the bolts are tightened.

This is DEFINITELY going to one hell of a learning experience, lol!

That makes more sense to me... I plan to swap essentially EVERYTHING over, cover, res/gasket, oil pickup, and the new (superduty) oil pan.

When I did my forged rod swap I used an E99. Only the drivers side manifold is different. Pretty sure all 7.3's have an identical passenger manifold.

And X2 on using a ford manual. PSN used to have one in their library.

Any different from these?


Engine Dis-assembly

Engine Assembly

Engine Specification

 

[juniort444e]

Op, someone already said it. But i will repeat just because i can.

On the 95, where the oil pickup tube attached to the front cover it was on the opposite side as my 01 motor. Could be the old style or just from being different for the bus. Who knows, I don't.

But like what was stated, if you have all the newer stuff then use it all in the swap. Oh and don't rtv the oil pan until you are 100% sure it won't need pulled back off. :banghead:

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[Big Bore]

Pickup tube location was allegedly changed to make oil pickup more efficient iirc.

 

[ToMang07]

NEEDED New Parts/Gaskets:
RTV Silicone Sealant. (F5TZ-19G204-AB)
New Head Gaskets.
*New Front Cover Gaskets needed???
*New Engine Mounts Needed???
*New HPOP Gasket Needed???
*New Oil Cooler Block Gaskets Needed??? (Recently Replaced)
New OEM Oil Pan.
New OEM Water Pump.
New Injector O-Rings
New OEM Glow Plugs.

Tools:
2-Ton Cherry Picker.
2k lb Engine stand.
Damper Remover/Replacer (Links to which one works? @Harbor Freight)
HPOP Line Disconnect tool
*Head lifting Tool. (Needed???)
*Injector Removal Tool. (Needed???)
*Injector Install Tool. (Needed???)
Oil Suction Tool.

Also, for installing the cylinder heads, the directions (vaugely) say "Using the special tools, install the cylinder head." WTF are they referring to???? (Page 26 on the above linked assembly instructions.) Is that just the lift bracket???

Am I missing anything? Comments/suggestions are VERY welcomed! opcorn:

 

[ToMang07]

Op, someone already said it. But i will repeat just because i can.

On the 95, where the oil pickup tube attached to the front cover it was on the opposite side as my 01 motor. Could be the old style or just from being different for the bus. Who knows, I don't.

But like what was stated, if you have all the newer stuff then use it all in the swap. Oh and don't rtv the oil pan until you are 100% sure it won't need pulled back off. :banghead:

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HAHA, I'm sensing a "damnit" happened! (I'm sure I'll have a few, hopefully small ones!)

Pickup tube location was allegedly changed to make oil pickup more efficient iirc.

That was my understanding as well....that and the difference in pan depths.

Thanks for the continued input, all! :bowfast:

 

[ToMang07]

So after talking to a fellow member... I have an entirely new idea that I had not thought of:

Since I have to take the heads and oil pan off anyway...

Why not remove the rods bolts from the bottom of the block... And remove the pistons/rods through the top. Switch out the rods (and maybe pistons) and viola, I can keep my block, most of the parts on it, and save myself a lot of time/work without touching the crank! Original engine....holy ****... didn't even know that was possible....but it make SOOO much more sense!

So... yeah... I think I have a (surprise surprise) new plan! Thoughts/input???

 

[Chvyrkr]

We swapped an E99 into an 02 last year and the manifolds did not need to be swapped. I'm almost positive the passenger side manifold on an OBS motor has to be changed to an E99 or later. Too much crap going through my head lately but I would swear on that one.

OP, your late model engine has a filter in the HPOP reservoir gasket, the cover is different in the gasket mounting area vs the OBS cover to allow for that integral filter in the gasket. Highly recommended. However earlier covers had the oil pickup to the pan on the opposite side, that pickup connects to the front cover. The oil pan was also changed in order to accommodate the new pickup tube location. So, as long as you keep the same years together you should be good.

If you don't want to remove the cover (understandable since it's a considerable amount of work) then don't worry about it. Just remeber to get the HPOP reservoir gasket for the year of the cover, not the truck, using a filter gasket on the early front cover will crack the cover when the bolts are tightened.

Hmm... Well, at the risk of giving away how redneck I can be at times...

The passenger side manifold on that engine wouldn't come loose. Broke a stud off even with the block, and started to twist a second off, so the passenger side on that E99 block stayed there. I originally planned to swap both manifolds, as my 02's were in much better condition. I eventually had every stud drilled out and heli-coiled on the passenger side. Do yourself a favor and never install and engine with something questionable, just because you need the truck...

The drivers side manifold on the E99 I had was definately different. I don't remember which anymore, but either the E99 mani or the 02 mani has a slightly different turn up, and requires a longer up-pipe.

So after talking to a fellow member... I have an entirely new idea that I had not thought of:

Since I have to take the heads and oil pan off anyway...

Why not remove the rods bolts from the bottom of the block... And remove the pistons/rods through the top. Switch out the rods (and maybe pistons) and viola, I can keep my block, most of the parts on it, and save myself a lot of time/work without touching the crank! Original engine....holy ****... didn't even know that was possible....but it make SOOO much more sense!

So... yeah... I think I have a (surprise surprise) new plan! Thoughts/input???

The rotating assembly needs to be balanced brother.

Wish is was that easy though.

 

[ToMang07]

Hmm... Well, at the risk of giving away how redneck I can be at times...

The passenger side manifold on that engine wouldn't come loose. Broke a stud off even with the block, and started to twist a second off, so the passenger side on that E99 block stayed there. I originally planned to swap both manifolds, as my 02's were in much better condition. I eventually had every stud drilled out and heli-coiled on the passenger side. Do yourself a favor and never install and engine with something questionable, just because you need the truck...

The drivers side manifold on the E99 I had was definately different. I don't remember which anymore, but either the E99 mani or the 02 mani has a slightly different turn up, and requires a longer up-pipe.

The rotating assembly needs to be balanced brother.

Wish is was that easy though.

You aren't the first to bring up the manifold bolts snapping... and considering they are $500... I'm thinking I'll pass on them. I really would like new ones... but finding a shop and dealing with busted bolts or stripped heads.... not really going to help the "cost" factor.

I am looking into getting new piston rings and a hone, but at this point I will re-use the pistons with the new rods.

I hear what you are saying Tom about balancing the rotating assembly... but I think I'm going to have to chance it... honestly the majority of the balancing won't be effected by rods anyway, will it, since they should be putting the same amounts of force on it as before? (From compression?)

Honestly, either way it's not in the cards. After buying parts, I'm pretty much going to be tapped out. :lookaround:

Thanks for the input tho, I really do appreciate it! :thumbup:

Here is my projected parts order list:

Complete CAC Intercooler Boot Kit

OEM Powerstroke Water Pump
+Upper and Lower Radiator Hoses

Motorcraft Glowplugs (8)

Alliant Injector O-rings (8)

Ford Head Gasket 94.5-03 (2)

FoMoCo Oil Pan 99-03 (1)

Melling Low Pressure Oil Pump LPOP (1)

ARP 7.3L Headstud Kit (1)

Comp Cams 910-16 Valve Spring Set (1)

Fel-Pro Up-pipe Gasket (2)

Motorcraft RTV Silicone Sealant (1)