How do you swap engine out of 1998 Ford Expedition?

Answer 1

Engine Swap: Tips and Tricks Forewarned is forearmed By: Phil Coconis/autoMedia.com Once you understand the basics of what's involved when replacing an engine, whether or not you've decided to go ahead with the project, here are some tips and tricks to help you with the actual mechanical procedure.

Tools | Back To Top

First, you're going to need a comprehensive set of hand tools and, ideally, even some air tools. You should also consult a service manual for your vehicle, which describes the step-by-step procedure for removal and replacement (R&R) of the engine, including safety precautions and special equipment needed.

Space | Back To Top

Keep in mind that this sort of job may mean that you'll be a "weekend warrior" for the next month or so, and you need to secure the appropriate paved work/storage area to wage your "warfare." It's also good to understand that the point of this whole exercise may have more to do with engaging in satisfying manual work than actually saving lots of money on labor fees.

Hints | Back To Top

Given that, you're well on your way toward actually doing the job. Before proceeding, though, you may find the following principles, hints, and bits of wisdom welcome, since forewarned is forearmed, as the old saying goes.

Safety | Back To Top

If you're not already well aware of this, engine R&R is one of the more potentially hazardous procedures that can be performed on a vehicle. Working in close proximity with large, heavy objects suspended by rigging attached to a hydraulic lift is actually a trade in itself, so if you really don't have a feel for this kind of thing, enlist the help of someone who does. Even if you have all of the skills required, you're probably still going to need a helper for at least some of the individual procedures. Trying to remove a hood, for instance, would definitely call for some back up. It's not recommended that you solo any procedure you're uncomfortable with from a safety perspective.

Patience | Back To Top

You'll need this quality throughout the entire job, from inspecting the used engine for quality and compatibility to filling the fluids properly, and much in between. For instance, even if the used engine appears to be an exact or acceptable match, don't start any prep work on it until you've removed the old engine and have it side-by-side with the good one.

Details | Back To Top

Then carefully check details such as flywheel-to-crankshaft compatibility, exhaust manifold configuration, ancillary component location (including sensors), and external coolant Plumbing configuration. Sometimes apparent discrepancies in these details can be corrected easily simply by transferring the old part(s) to the good used engine. And sometimes not-you'll have to determine this firsthand and work out the best solution, which may involve requesting another engine.

Fluids | Back To Top

In addition, take the time to drain all of the applicable fluids before the actual removal of the engine/transmission assembly. This would especially include draining coolant from the engine block, via the block drain plugs-unless they're just too inaccessible. You'll avoid making a slippery, potentially dangerous mess unnecessarily.

Disassembly | Back To Top

Obviously, you'll have to disassemble the engine somewhat in order to safely remove it from the engine bay. How much disassembly is required will be determined by many factors. These include whether the transmission can or should be removed at the same time, which old parts have to be transferred to the good used engine, and which direction it'll be removed (top, bottom or front of the vehicle). Don't forget the type of removal equipment you will be using as well.

Components | Back To Top

Make sure that all relevant hoses, cables, linkages, mounts and stabilizers, electrical connectors, and other components are properly disconnected at the simplest, most accessible points. If any of these components are dangling or protruding into the removal path of the engine assembly, they should be tied out of the way. Plastic cable ties work excellently for this. It is very important that this is done before any attempts are made to lift the engine assembly from its installed position.

Engine Lift | Back To Top

Keep in mind that as you are lifting the engine assembly, and make sure that there is nothing still connected, there is no component interference, and lift angles are correct. Since these factors seem to change by the inch, it's not a bad idea to have that hawkeyed assistant of yours observing from the opposite side that you are working on. As you are progressing, it's extremely important to keep your cool and work under control. Do not force anything! Use your brain, and let the equipment do the heavy stuff. Life, limb, and property can be literally hanging in the balance.

Diligence | Back To Top

Closely related to patience, this quality can help your cause by leaving "no stone unturned" as you proceed through the litany of steps and procedures. As one example, the best time to take care of any potential or perceived problems with the replacement engine and related components is before you begin installing it.

Are the oil seals showing signs of leakage? The crankshaft rear main seal is easy to replace now-much tougher to do later. Ditto for the clutch assembly and flywheel, if so equipped. It doesn't make sense to reinstall a clutch assembly that is mostly worn, since you'll pretty much be paying only for the parts if you decide to replace them now. If the engine is equipped with a timing belt, it should be replaced, as well as other related components. The water pump and thermostat should be replaced, as well as all coolant hoses. The radiator should be pressure- and flow-tested. Make a thorough inspection of all "wear" components on the engine and in the engine bay and repair/replace as needed.

If you're fortunate, there may be some serviceable components that came attached to the replacement engine. If they're in better condition than the old components, use them; and save the money that would have been spent on new ones.

Review | Back To Top

At the end of each procedure, review what you have done. Are the parts installed correctly and the fasteners properly tightened? Anything missing? Any steps omitted?

Looking at the job from a conceptual point of view, the "big picture," will take your skills to a new level. This is how professional mechanics approach a complicated job like this, so they can remember where all of the nuts, bolts, and components fit, without missing a trick. Follow these same principles, and you can do the same.

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