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1979-2004 V6 Mustang Tech Discussions

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Unread 03-09-2011   #1 (permalink)
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Default 2001 Mustang V6 to 2001 Mustang 4.6 Swap

For all those Sixxers out there that want to upgrade to the 4.6..

My Strength is in electrical,so my research on this has been time consuming, and i have already started my project..

This write up is based on the 2001 4.6 5spd into a 2001 3.8 5spd car..
if you are interested in doing this swap into a different year, let me know the year of the project car and donner, only years 98-04 4.6,

If you have a complete donner GT then that would be the best, if not this is what you will need....(want) I found a donner for $1300.00
Before you start, this isnt a swap for anyone that is NOT mechanically inclined or know a few things about vehicle wireing...

Easy: skill level 6/10 not for the noobies...

The vehicle will be turn key if you change these out from the donner car, or reflash from dealer will be necessary..
(1) GT gauge cluster..has immoblizer coded into it...
(2)Ignition switch with key, chip in key matches gauge cluster immobizer
(3)GT PCM
(4)4.6 engine with harness
(5)manual trans(clutch cable cross member works from 3.8)
(6)8.8 rear end, stock 7.5 will work but upgrade...

The 00-02 mustangs v6 and v8 both have the same 104 pin pcm and connector, not sure if they are the same on the years before 00 and after 02, this write up in on a 2001.

Between the two engines, the engine harness has the same large square connector thats located in the corner of the passenger side fender, with a smaller sub connector.

All the pin outs on the 3.8 and the 4.6 PCM are identical, except the 3.8 is missing a few of the 4.6 engine controls, such as injectors #7 and #8 (missing) coil on plugs 2-8, ground, ECT, A/C high pressure control switch, and a few wires need to be swapped into other pin slots..


The bottom line is that its only 62 wires that run the 4.6 including A/C, and fan control (NOT COUNTING THE WIRES THAT RUN THE 4R70W), and 46 wires on the 3.8 are identical, wire color and pin outs, all you would need to do is over lay the remaining 16 wires, which might seem like a chore, but a little time and patents your done.. ALTHOUGH THE 3.8 AND THE 4.6 SHARE THE SAME PINS FOR THE 4R70W, So if running the auto, the engine/trans harness will be needed, plug and play...

The A/C lines will need changed from the 4.6 due to how the lines are formed, the heater hoses are the same that run into the fire wall, (2 quick disconnect fittings)
the radiators are the same, although the gt has a large external coolant resivour, that sits on top of the radiator, but the 3.8 will work. If im missing something please ask and i will add, its alot different to do it then to type it, lol
-----------------------------------------------------------------------------------------------
FACTS:
(1) the 4.6 and 5 spd will bolt right into the 3.8 chassis, no mods needed
(2) the 4.6 pcm plugs into the 3.8 harness, again 16 wires will need to be added,
(3)reflash pcm, or install gauge cluster, ignition switch and key that came from donner vehicle...
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Unread 03-09-2011   #2 (permalink)
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alot of good information there.. thanks for posting
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Unread 03-09-2011   #3 (permalink)
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Do you by chance know if the firewall harness is the same on all models 96-04? The harness from the eec to the bolted connector next to the a/c canister.
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Unread 03-09-2011   #4 (permalink)
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Not sure if I read it correctly, but are you using the 3.8L engine harness and then just added the required sections from the GT harness?

If this is what you did, does the existing 3.8L wirring have enough length to reach certain sensors on the 4.6L? Are the sensors in the same same general location between the 2 engines?
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Best ET: 15.44@91 mph (on 18's)
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Unread 03-09-2011   #5 (permalink)
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you want to use the complete gt engine management harnesss, the sub harness from the 3.8 PCM to that square connector block is missing those extra wires to run the 4.6, so you will need to add some wires, when i go into work tomorrow i will upload the seperate pin outs of both engines so you can compare the two...its not as hard as it sounds...
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Unread 03-09-2011   #6 (permalink)
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Quote:
Originally Posted by metalman302 View Post
Do you by chance know if the firewall harness is the same on all models 96-04? The harness from the eec to the bolted connector next to the a/c canister.


i will find out , im sure they are the same, connector for the pcm may have changed from the 96 body to the 98-04, i will look into it, if the pcm connector is the same, then same concept,
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Unread 03-10-2011   #7 (permalink)
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Makes a little more sense. I didn't think you were using the 3.8L harness.
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408W In the Works
TW FAC's, Jay Allen cam, Super Victor

2001 V6 5 Speed Daily Driver
Windstar Intake, Dual Exhuast, CAI, Headers
Best ET: 15.44@91 mph (on 18's)
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Unread 03-10-2011   #8 (permalink)
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quick question. what would it cost to have a mechanic do everything about if i have a donner car?
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Unread 03-10-2011   #9 (permalink)
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Quote:
Originally Posted by iYi CLUTCH iYi View Post
quick question. what would it cost to have a mechanic do everything about if i have a donner car?

Well considering the fact that I'm a mechanic and the shop I work for charges 100 per hour, they will charge book time for the engine and transmission install, which is around 22 hrs give or take, than the added time for electrical work, so a ball park would be around 3000 ,if you had all parts , but if you had a shop pull your donner apart at well , maybe another 1000, I charged someone about 2500 to do an ls1 swap into an s10 truck, and that was just labor, so it really all depends on who does it, cheaper if you at least install everything, and had someone wire it ..
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Unread 03-10-2011   #10 (permalink)
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Default 3.8 pin out

2001 3.8 pin outs for engine and transmission
2001 4.6 pin outs for engine and transmission
Attached Thumbnails
2001 Mustang V6 to 2001 Mustang 4.6 Swap-3.8.gif  2001 Mustang V6 to 2001 Mustang 4.6 Swap-3.8-2-.gif  2001 Mustang V6 to 2001 Mustang 4.6 Swap-4.6.gif  2001 Mustang V6 to 2001 Mustang 4.6 Swap-4.6-2-.gif  
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Unread 03-10-2011   #11 (permalink)
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You're forgetting that you also need to swap out the Hydroboost brake setup from the GT into the V6 since the vacuum booster will hit the drivers side head. This swap should not be attempted by people with little mechanical skills and if you only charged $3K for all that work you are selling yourself short. The brake booster swap alone is another 2 hours or so.
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Numbers to come when I get it on the road.....
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Unread 03-10-2011   #12 (permalink)
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Quote:
Originally Posted by b1lk1 View Post
You're forgetting that you also need to swap out the Hydroboost brake setup from the GT into the V6 since the vacuum booster will hit the drivers side head. This swap should not be attempted by people with little mechanical skills and if you only charged $3K for all that work you are selling yourself short. The brake booster swap alone is another 2 hours or so.

Yes the hydoboost was a big thing left out, thanks for the save, as far the cost of me doing that swap, as far as doing a swap like that for 3k, must rather do that on a slow week then nothing at all, money is money, but for the average joe, I sure dont suggest doing this swap, especially when it comes to the electical, got to be gifted to mess with that, lol..
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Unread 03-10-2011   #13 (permalink)
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I personally would not do this level of a swap for anyone for under $3K directly in my pocket. This is the reason I work for myself and not a shop, I can't accept the fact I am making money for anyone else but myself (and the government of course, lol). Mechanics get paid crapola compared to what the world think we get. The shop makes a LOT of money off the backs of others. Sure they have to cover all the overhead, but considering the highest paid techs are barely touching $30 an hour yet have to spend 1/2 their pay on constant training and tool upgrades it is hardly worthwhile. To me, you gotta really love the job to do it.
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Unread 03-11-2011   #14 (permalink)
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Quote:
Originally Posted by b1lk1 View Post
but considering the highest paid techs are barely touching $30 an hour yet have to spend 1/2 their pay on constant training and tool upgrades it is hardly worthwhile. To me, you gotta really love the job to do it.
Exactly why I got out of it. I'm training for X-ray now, I'm going to start closer to that rate right out of school then if I had stayed with Ford or Land Rover for years before I would get close to that pay.
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90 LX, Previous 4 cyl.
408W In the Works
TW FAC's, Jay Allen cam, Super Victor

2001 V6 5 Speed Daily Driver
Windstar Intake, Dual Exhuast, CAI, Headers
Best ET: 15.44@91 mph (on 18's)
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