Well-traveled 2002 Ford F-150 Gets Much-needed Engine Swap

While most folks with a tired engine would simply get rid of it, one F-150 Online member works hard to fix it.

When trucks begin to show signs of age or experience mechanical issues, most owners simply move on to a newer truck. But that isn’t the case with many members here in the F-150 Online Forums. Here, folks have a love affair with their trucks that can’t be broken by silly things like an engine that’s best served with a replacement. And in the case of member zjrog, he’s willing to put in the work to keep his beloved 2002 Ford F-150 Super Crew on the road.

“I’m preparing to swap engines in my 2002 F-150. What I have is an oil-starved top end on the original 5.4 with about 150,000 miles. I will be picking up a 175,000-mile fleet-maintained 5.4 from a 2001 F-350. Plans are to tear down of the ’01 engine and replace the bearings, gaskets, and seals. Wish I had a chance to to do a compression test and leak down, but I don’t know how to do that without installing it first.”

Soon, the engine came in and the OP got to work tearing it down. And upon initial inspection, the new 5.4 certainly looked pretty good inside. As well as a little bit different.

“I am quite surprised how many things are different between the F-150 version and the Super Duty. I’m planning on adding a remote dual filter setup and swapping in new oil and water pumps. I’m undecided on removing the heads and replacing the head gaskets, but that’s probably a good idea.”

Some time passed before the OP made any more progress on his F-150 engine swap. As if often does, life simply got in the way. But soon, he was ready to get going and had accumulated a slew of new parts for the project. After cleaning up the inside, he replaced the head and exhaust manifold gaskets and bolts first. Then, he added a new timing set, oil and water pumps, lifters, sensors, and a heating tube.

At this point, the old engine is out of the OP’s F-150. And he’s working on making the new one fit. Which is proving to be a little bit of a challenge since there are a few differences between the F-150 and Super Duty versions of the 5.4-liter V8. So be sure and head over here to keep up with this cool project. And while you’re there, add any advice you may have to help make this process go a little smoother!

Photos: F-150 Online Forums

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Brett Foote

Brett Foote has been covering the automotive industry for over five years and is a longtime contributor to Internet Brands’ Auto Group sites, including Chevrolet Forum, Rennlist, and Ford Truck Enthusiasts, among other popular sites.

He has been an automotive enthusiast since the day he came into this world and rode home from the hospital in a first-gen Mustang, and he's been wrenching on them nearly as long.

In addition to his expertise writing about cars, trucks, motorcycles, and every other type of automobile, Brett had spent several years running parts for local auto dealerships.

You can follow along with his builds and various automotive shenanigans on Instagram: @bfoote.