E36 V8 Swap Part 6: Replacement Engine Acquisition

"MikaelVroom" (mikaelvroom) 05/23/2016 at 09:23 • Filed to: None

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Many build logs have been written detailing impeccable craftsmanship, exquisite attention to detail, and unmatched performance. This is not one of those build logs. This is a continuation of my project involving shoving an outdated, underpowered engine into a rusty, beat up car. In the last installment, I detailed pulling the car’s original, destroyed engine out.

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With the old, demolished engine out of the car it was time to prep the replacement engine. But wait a tick - what engine will be used in place of the German engineered-to-perfection-except-for-the-oil-pump-nut BMW inline six? In short, I did this whole thing backwards. A proper, well-thought-out car build would start with careful consideration and selection of the donor car after an exhaustive inspection of the donor’s condition, intensive research into the most cost-effective, widely-supported modifications, and then throwing out the idea of doing an engine swap all together because it makes no sense. I did none of that. I started by buying an engine. Consider this installment a prequel to part 1.

A consequence of frequent travel for work is frequent downtime in hotels in various cities around the world. A savvy traveler would take advantage of that marvelous opportunity to explore a new city, see the sights, spend time getting to know the local people, customs, and food, and enriching his or her life through these experiences. Not me. I sit in my hotel room and browse Craigslist for cars with salvage titles. At some point, though, I must have gotten bored of Craigslist and ventured over to car-part.com, “Your #1 Resource for Finding Used Car Parts and Also Seeing if There are Enough Wrecked Ecoboost F150s Out There Yet So That Prices on the Twin Turbo 3.5 Have Come Down to Something Reasonable Now.”

Out of the blue, I noticed that a wrecking yard about 30 miles away from home had a 5.0 engine from a ‘97 Explorer listed for $250. As soon as I could get home and borrow a trailer I immediately went up and bought it.

With core charges and tax and everything it came out to right around $300. Although I had no reason to own a V8 engine, I did. What does a $300 160,000 mile junkyard V8 look like? Just like this:

The Explorer engine actually has a few advantages when it comes to engine swaps. The front accessories are more compact than other 5.0 setups by an inch or two, buying space. The Explorer has a built-in 90 degree adapter/cooler for the oil filter making it fit within many cars’ frame rails. The engine was set up for Ford’s EDIS ignition so instead of a distributor it has a cam position sensor. On top of that, it has a 36-1 tooth crank VR sensor built in for aftermarket ECU flexibility.

The Explorer intake is considered to be roughly equivalent to the GT-40/Cobra intake that flows nearly as well as - !!!error: Indecipherable SUB-paragraph formatting!!! - any aftermarket intake, and the Explorer engine came with either the GT40 or GT40P heads, which were arguably Ford’s best factory head for the 5.0, standard on the ‘93 Cobra and Lightning.

Well, a couple weeks later I found myself in the Chicago area for work. Every day on the way to work I passed a place called “Pick N Pull.” I’d heard rumors of the existence of these types of scrapyards - bring your own tools, pull your own parts, try not to get squished by a poorly-propped up car falling down on top of you. A quick perusal of their online price list let me know that I could get any manual transmission my heart desired for $100. So after work one day I stopped by, paid the nominal $2 entry fee, signed my life away on the waiver form, and took a look around.

Lemons racecar, Lemons racecar, Lemons racecar, Lemons racecar...

I was in heaven. Busted up cars poorly propped up and ripe for some parts-pullin’ (and possibly body-squishin’) action.

Now I knew the only good option for a manual transmission compatible with my engine was a Mustang equipped with a T5 transmission. Viable candidates were available in the Mustang GT starting in the early ‘80s through ‘95, and in the V6 model between ‘94 and ‘04. They came in varying input shaft lengths, strengths, and gear ratio sets, noting that the ‘99-’04 V6 T5s were identical in strength to the ‘94-’95 V8 with the added bonus of an electronic speedo sender, !!!error: Indecipherable SUB-paragraph formatting!!! . On top of that, Any T5 behind a V6 is probably less abused than one behind a V8 car.

This Pick N Pull had a few Mustangs, but nothing with a manual transmission. Fortunately there was another location across town, so the next day after work I headed through the sketchy outskirts of Chicago during rush hour (like Harbor Freight, somehow wrecking yards are rarely in the nice parts of town) and found it with about 30 minutes until closing time. This one actually had two V6 Mustangs with manual transmissions - a ‘99 and an ‘04. Jackpot. Bingo. Shazam. Nailed it.

I left and went straight to the nearest Wal-Mart and bought a socket set, a pry-bar, and a crescent wrench. Perusal of several online “How do I pull my transmission” posts revealed that I’d need a 12mm 12-point socket to get the driveshaft bolts off of the rear end flange, so I grabbed one of those at Menards, along with a set of 3/8" u-joint attachments.

The next day after work I again had about a half hour until closing time. I was able to get the driveshaft pulled and three of the four transmission-to-bellhousing bolts pulled, most of which required getting the ratchet on the bolt, then lying on my back and furiously kicking at the ratchet handle until the bolts broke free, all the while hoping the car didn’t fall down and slice me in half. The next day was my last day of work in Chicago and I finished up first thing in the morning, so I headed back to Pick N Pull for the third time. With the last bolt finally free, it was time for the transmission to drop.

It’s story time. Back in high school I ran cross country. At the end of each day’s workout we’d hit the weight room. On more than one occasion, the junior high girls would make fun of me because they were benching more than I was. That is the level of arm strength I’m working with. I’m probably stronger now than I was in high school, but when the internet tells me the T5 weighs about 75lbs, I’m not about to risk the integrity of my torso trying to prove my manliness by bench pressing an awkwardly-shaped oversized hulk of metal just to stick it to some junior high girls. So I put an old tire and a back seat from a Jetta directly under the transmission and yanked it straight back so that it would fall down onto my makeshift trampoline.

I nabbed the shifter, boot, crossmember, bolts, the electrical pigtails, threw it all into the wheelbarrow, and headed in to pay.

The total with core charges and everything was about $150.

Now I had a engine and a transmission, but no way to connect the two - the V6 and V8 bellhousings are different. The ‘94-up Mustangs used a longer input shaft (to place the shifter in the correct location for the redesigned ‘94-up cars), so using an ‘04 transmission behind the V8 meant I needed a ‘94-’95 V8 bellhousing, which typically go for $150 or more on eBay. Back to car-part.com. I found one in a nearby Omaha at a scrapyard listed for $100, so I called and had them ship it to me. As they were packing it up they saw what they thought were hairline fractures, so they gave it to me for $75. Turns out they were just casting marks. Score.

Looks like $25 off to me.

And for the next six months, the drivetrain sat in my garage, unsure of its fate.

Until one day when the perfect candidate for a V8 swap !!!error: Indecipherable SUB-paragraph formatting!!! .

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Catch my build thread here on Oppo with a new installment each Monday, or if you like spoilers check out !!!error: Indecipherable SUB-paragraph formatting!!! for the latest updates. Twitter me !!!error: Indecipherable SUB-paragraph formatting!!! , Instagram me !!!error: Indecipherable SUB-paragraph formatting!!! . My wife calls my Instagram feed “boring,” which I take as a compliment.

GrannyShifter (don't judge my Hofmeister kink) > MikaelVroom 05/23/2016 at 11:40

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most of which required getting the ratchet on the bolt, then lying on my back and furiously kicking at the ratchet handle until the bolts broke free, all the while hoping the car didn’t fall down and slice me in half.

60% of the time, this works every time.

Have Jeep, will travel. > MikaelVroom 05/23/2016 at 11:43

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You had a problem with the oil pump nut? Its been common knowledge for a long time to replace it and safety wire it to the drive sprocket. Ouch.

MikaelVroom > Have Jeep, will travel. 05/23/2016 at 11:46

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Tell that to the previous owner!!

MikaelVroom > GrannyShifter (don't judge my Hofmeister kink) 05/23/2016 at 11:48

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I’m pretty sure that’s the procedure in the Ford shop manual.

marshamallow > MikaelVroom 05/23/2016 at 11:50

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Pretty sure I would have opted for LY6-T56 combo.

Sixtimestodaysofar > GrannyShifter (don't judge my Hofmeister kink) 05/23/2016 at 11:54

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Or, sometimes every time this works 60%.

GrannyShifter (don't judge my Hofmeister kink) > MikaelVroom 05/23/2016 at 11:57

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Makes sense...Last time I did it, I was pulling the front axles on an Expedition.

aeOzzy > MikaelVroom 05/23/2016 at 12:00

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Eesh! You got lucky with those cast marks! Looking forward to the next article!

HarriH0oner > MikaelVroom 05/23/2016 at 12:03

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Is that a Nighthawk S I spy in that there garage? I definitely want one of those! Air-cooled and 6 speeds. Totes jelly!

MikaelVroom > marshamallow 05/23/2016 at 12:08

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Let me know where I can pick up that combo for $450 and I’m on board!

MikaelVroom > aeOzzy 05/23/2016 at 12:08

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I figured worst case scenario I’d have to learn to TIG weld.

MikaelVroom > HarriH0oner 05/23/2016 at 12:10

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Yes! I was given two parts bikes for free, so I picked the best parts from the two, and built one good bike topped off with the ‘86 red white and blue color scheme. Then I converted it to a rear disc brake, installed 17" wheels, a CBR master cylinder, and more. I have a disease.

Quade > MikaelVroom 05/23/2016 at 12:14

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Engine and transmission are the best part of the E36. It’s the rest of the car that’s garbage. Still they drive well and have huge aftermarket support.

Read up on “rtab pockets”. It’s better to weld them up before they crack than after. If they fail, the rear trailing arm will fall off.

Watch the rear diff too. It’s only got one bolt in front to hold it and they tend to snap. Common upgrade is to open up the bushing, drill and tap the hole bigger on the diff and to use a larger bolt.

MikaelVroom > Quade 05/23/2016 at 12:25

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Check my previous posts, the car already has RTAB limiters and plates welded in!

Dr.Kamiya > MikaelVroom 05/23/2016 at 12:26

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Sweet writeup dude!

Looking forward to hearing about you rolling in your 5.0.

OldManMcKenna > MikaelVroom 05/23/2016 at 12:27

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Dude, you’re totally doing it right re: garage contents. Also, I dig the swap partly because I am a fan of the 5.0 Ford (I’ve put a few into Volvos), and partly for how much it pisses off purists. Kudos on all fronts.

CalBearsFan99 > MikaelVroom 05/23/2016 at 12:28

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Makes you wonder how many accidents happen at Pick-n-Pulls or other junkyards.

marshamallow > MikaelVroom 05/23/2016 at 12:28

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I’m totally ok with your approach on this build, I just have a differing opinions. IMO, If I’m going to put my time and effort into a swap, I’m going to do it with decent parts that are capable of putting down halfway impressive numbers. But then there’s the whole value triangle thingy....

Quade > MikaelVroom 05/23/2016 at 12:30

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Nice! Cost me a grand to have that done because I didn’t own a welder at the time and the place I had do it removed the fuel tank because they were afraid to weld too close to it. I still think a metal shield while welding would have been enough...

MikaelVroom > Dr.Kamiya 05/23/2016 at 12:36

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With my sunroof open so my hair can blow...until I get tired of wind whipping around and close the sunroof because that is a more reasonable choice.

MikaelVroom > OldManMcKenna 05/23/2016 at 12:37

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The crown jewel of the garage is, of course, the bubble-producing lawn mower.

MikaelVroom > CalBearsFan99 05/23/2016 at 12:38

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There are a couple times that I’ve refused to get under a car after lightly pushing on it and watching it rock from side to side.

MikaelVroom > marshamallow 05/23/2016 at 12:40

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The 5.0 is easily capable of 400hp NA, and the whole setup is a good 100lbs less than the LS/T56 combo. That’s more than enough for DD/autocross duty!

marshamallow > MikaelVroom 05/23/2016 at 12:40

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Goals are always an important part of the build!

lone_liberal > MikaelVroom 05/23/2016 at 12:41

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The other advantage a Windsor Ford has is that it’s pretty compact, especially the 302 and smaller, so it is an easier fit in to tight engine compartments.

turbo_corolla > OldManMcKenna 05/23/2016 at 12:41

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Wanna put one in my ranger? I have beer.

MikaelVroom > lone_liberal 05/23/2016 at 12:51

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Compact to more easily fit into tight spaces? That’s my jam.

OldManMcKenna > turbo_corolla 05/23/2016 at 12:57

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I currently have another project that takes 100% of my free time - a 1 year old human. Prior to 2 weekends ago rebuilding the front suspension on my ‘98 4Runner and all 4 corners worth of brakes (calipers, pads, rotors, lines) on my ‘98 Volvo, I hadn’t turned a wrench in 8 months. But in 17 years, I’ll be available.

turbo_corolla > OldManMcKenna 05/23/2016 at 13:06

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Haha I completely understand, I have an 8 year old.

Garrett Davis > MikaelVroom 05/23/2016 at 13:07

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This is awesome, I’ll definitely be watching this build!

FiveLiters1 > MikaelVroom 05/23/2016 at 13:33

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Question:when you get a part,such as a transmission like you did,how do you know it works? I have a 5.0 auto that is going to be converted to a stick,and I’m buying a remanufactured one from a shop that only deals with Mustangs,and it comes with a warranty. I’m obviously paying more than $225,but if I went through the trouble of yanking a tranny or engine and installing it,only to find it isn’t working (my current one isn’t working,which is why I decided to go this route)...I’d be more pissed than R. Kelly at a middle school sleepover. EIther way,looking forward to hearing how this goes!

WJRo > MikaelVroom 05/23/2016 at 13:46

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Is that a 700sc nighthawk?

Kenkura > MikaelVroom 05/23/2016 at 13:49

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not sure what you are planning to do ECU wise but I wouldnt waste your time or budget on an aftermarket standalone ecu, Ford EEC 4/5 ECUs are quite capable and are well documented, you can buy everythign you need to tune it yourself for about $400.

http://www.moates.net/quarterhorse-f… +

http://www.eecanalyzer.net/be + http://eectuning.org/forums/

nurkerman > OldManMcKenna 05/23/2016 at 13:56

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Im also partial to a 5.0, my foxbody’s has over 200k and is still a powerful and surprisingly reliable motor. My buddy just bought a 1977 volvo 242 and we’re planning a 5.0 swap, any advice you’d care to share?

 > MikaelVroom 05/23/2016 at 13:57

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I hope you plan to dump the truck cam.

HarriH0oner > MikaelVroom 05/23/2016 at 13:58

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I had an 86 450 that I got for $800. Replaced a lot of that bike. Every time I took something off, it got polished or painted and put back on. Popped a 15 tooth front sprocket on so there was enough grunt for 6th gear. New clutches, springs, brakes. Re-jetted carbs and new exhaust. She would hum at highway speeds and easily due the ton if needed. Ended up selling it for 3 x what I paid. Love the old Nighthawks.

MikaelVroom > FiveLiters1 05/23/2016 at 14:16

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The yard offers a warranty that’s good for something like 30 or 60 days. They mark the part when you pay for it and if it doesn’t work, hopefully you can find another one in the yard that will work so you can pull that one and trade.

I hedged my bets by picking the newest one I could find, behind a V6 so it didn’t have to hold as much power, and the car it came from was obviously wrecked so that mechanical failure wasn’t part of why the car was in the yard.

MikaelVroom > WJRo 05/23/2016 at 14:16

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Yes! Total rebuild on that bike from scratch.

MikaelVroom > Kenkura 05/23/2016 at 14:19

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You’ll find out more about the ECU in the next couple of weeks!

MikaelVroom >  05/23/2016 at 14:20

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It will be perfect for towing my boat.

General Mayhem > MikaelVroom 05/23/2016 at 14:26

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Find yourself a March 2016 Car Craft, there’s an article on fixing up an Explorer 5.0L. It’s cheap and stupid easy to get HP out of them, they got an easy 325hp with a FRPP B303 cam, a dual-plane intake and a Holley Street Avenger carb.

General Mayhem > General Mayhem 05/23/2016 at 14:28

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And BTW, as a Ford guy I’m seriously digging this swap. Not another bellybutton LS swap.

OZI > MikaelVroom 05/23/2016 at 14:36

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I moved from Atlanta to Chicago not too long ago and I’m super glad this post involved yards around Chicago! Now I know where I can go when I’m bored. I used to go to Pull-A-Part all the time in Atlanta with a friend.

It’s a lot more fun than normal people think it is.

MikaelVroom > General Mayhem 05/23/2016 at 14:39

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I’ll look for it!!

MikaelVroom > General Mayhem 05/23/2016 at 14:39

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I’m about to re-gray anyone that suggests I should have used an LS.

MikaelVroom > OZI 05/23/2016 at 14:40

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It’s like a grade school field trip.

monkeyracing > OZI 05/23/2016 at 14:51

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I used to go walk around my local Pick Your Part when I was feeling down, or stressed. Much more relaxing than a park for me.

This as before they were bought out by the American chain “Pick n Pull” and started charging money., just to walk in the door. Funny story, those waiver sheets they make everyone sign are completely meaningless in Canada.

 > MikaelVroom 05/23/2016 at 14:55

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Not sure if serious.

NotUnlessRoundIsFunny > MikaelVroom 05/23/2016 at 15:06

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I am really, really enjoying this series. And, you’re a talented writer.

MikaelVroom > NotUnlessRoundIsFunny 05/23/2016 at 15:08

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I have to say, you’re a talented reader.

OldManMcKenna > nurkerman 05/23/2016 at 15:12

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All three of the swaps I was party to used 700/900 series Volvos, and all kept the Ford fuel injection. All I can recommend is the general/generic stuff ref: 200 series.

1. Brakes. Upgrade them first.
2. Suspension/steering. Make sure it’s tight, and can support the weight. It might look high enough when you first put the engine in, but after a while it’ll sag unless you use some kind of higher rated springs.
3. Make sure there isn’t any structural rust. If there is, take care of it before the engine goes in.
4. All of the standard suggestions about an LSD apply here.
5. Carb’d/Automatic trans is easiest. Fuel Injected/Manual trans is most fun. If you go fuel injected, get everything from the donor... all of the computers, harnesses etc.
6. As far as mounts go, Converse (Ross Converse, Converse engineering) used to make a kit back in the day. Not sure who does now.
7. Plan on fuel system and exhaust modifications.
8. This is by no means comprehensive. It’s been ~15 years since I worked on the last one. Google is a fantastic resource.

General Mayhem > MikaelVroom 05/23/2016 at 15:15

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:)

scramboleer > MikaelVroom 05/23/2016 at 15:34

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I love this game... find junkyard fuel-injected engine plus manual tranny and install in your choice of rig. Mine would be a 1947-1965 Willys pickup that someone already gave up on (plus axles and brakes), but I’m stoked to follow your project.

Oh, and as others have mentioned, those little people are a full-time project too. :) Our older one (3) loves the used bubble lawn mower someone gave to us. Now that was an easy project to fix up.

SyrianLanister > General Mayhem 05/23/2016 at 15:38

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Next step: 200 shot of nitrous

General Mayhem > SyrianLanister 05/23/2016 at 15:40

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I like how you think :) .

FiveLiters1 > MikaelVroom 05/23/2016 at 15:59

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That’s cool;I guess my concern was based on,using my car for example,if I’d have sent my car to the yard;to look at it,you’d have no idea the tranny was bad (motor is fine though),or that sometimes,depending on the hit,if something got jammed where it shouldn’t have and messed up other/internal parts.

(Also, you can never underestimate the foolishness of a teen with a V6 who wished they had a V8,and drives it like they’re on a racetrack!)

notthatGreg > MikaelVroom 05/23/2016 at 16:02

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This is fun to read, even when I run across paragraphs that might as well be in Sanskrit for as much of them as I comprehend. And it gives me something to look forward to Mondays for!

MikaelVroom > notthatGreg 05/23/2016 at 16:09

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NotUnlessRoundIsFunny > MikaelVroom 05/23/2016 at 16:45

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Aaaaand...you just made my point. :-)

notthatGreg > MikaelVroom 05/23/2016 at 16:59

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Exactly.

DirtMifflin > MikaelVroom 05/23/2016 at 17:45

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Excellent writing, interesting project, well done and good luck.

MikaelVroom > DirtMifflin 05/23/2016 at 17:52

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boxcarbob > FiveLiters1 05/23/2016 at 18:01

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middle school sleep over, you say.....hmmmm

ujiro11 > MikaelVroom 05/23/2016 at 18:37

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This is currently my favorite series/group of entries here on Jalopnik... Every time I see you’ve posted an article I get giddy to read it! You are taking on a type of project that I plan to one day as well, and your writing is fantastic. Keep it up. Can’t wait to read more!!

BobWellington > MikaelVroom 05/23/2016 at 20:16

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I just have to say that I absolutely love reading this. Can’t wait to see how it turns out.

kmoney > MikaelVroom 05/23/2016 at 23:02

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That CX500 in the background is awesome.

Darkshoe (With Straight 6) > MikaelVroom 05/24/2016 at 03:05

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Posts about long projects are why I read opposite lock. Also, you’re pretty good at writing! Keep it up.

Darkshoe (With Straight 6) > Darkshoe (With Straight 6) 05/24/2016 at 03:06

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Also, what is this “gray” thing and how do I get out of it?

Gubbin > MikaelVroom 05/24/2016 at 03:10

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Still trying to figure out the red Honda. CB550 or a late 70s twin maybe?

MikaelVroom > Darkshoe (With Straight 6) 05/24/2016 at 07:09

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Usually all it takes is unabashed flattery and I’ll ungray you, but I’ll take mild compliments, too.

MikaelVroom > Gubbin 05/24/2016 at 07:12

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‘72 CB450. Finally got it registered and running this season!

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MikaelVroom > kmoney 05/24/2016 at 07:17

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It’s probably one of my favorite bikes, probably because I didn’t try and modify it too much - Progressive suspension front and rear, some slightly lower bars, and some nice reverse cone mufflers.

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Phil > MikaelVroom 05/24/2016 at 08:57

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So you bought a V8 just for the sake of someday doing a V8 swap in an unidentified vehicle? You're my hero.

MikaelVroom > Phil 05/24/2016 at 09:01

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The GOVERNMENT, man - they’re coming for our V8s! Pretty soon we’re all going to be driving Chevy Volts made by GOVERNMENT MOTORS. But NOT ME. I’m stocked up.

notalec > kmoney 05/24/2016 at 12:29

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seriously. Can you start writing more about that whole collection of Honda bikes you’ve got?

Darkshoe (With Straight 6) > MikaelVroom 05/24/2016 at 14:19

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Thanks! Can't wait to read more about the project.

Darkshoe (With Straight 6) > MikaelVroom 05/24/2016 at 14:20

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I really hope you're serious.

PoPPaPork > MikaelVroom 05/24/2016 at 15:31

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Northstar or a 3800! :P

Gubbin > MikaelVroom 05/25/2016 at 13:37

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Beauty! And beastly, with the DOHC!

sklooner > MikaelVroom 05/30/2016 at 12:45

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I never have any luck with the do part of the job one day and return to picknpull- somebody else seems to find my mostly removed item and takes it for themself-

MikaelVroom > sklooner 05/30/2016 at 16:48

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I was terrified all day hoping that no one would swipe my stuff!