Progress Report: 302 V8 Swap

10/19-10/20 2003: I almost have enough room cleaned out in the barn to move the van in to take out the 302 V8. I am making excellent work on the barn, so hopefully tomorrow I will have the barn 90% cleaned out, and the van inside.

10/21-10/24: I didn't get the boat and van in the barn until the 23rd, but that's alright. On the 24th, I got the grill and and brackets off on the front of the van. I could have done more yesterday and today, but I was too tired from working all day (yes, I'm on fall break, so I worked because I needed the money) Tomorrow, my Dad and I will hopefully get the engine out.

10/25 2003: I drained the oil and coolant. Also, I pulled the oil cooler, transmission cooler, radiator, and fan shroud. Unfortunately, we didn't get the engine out, but that's because we didn't have time to get started on it, until after dinner.

10/26 2003: I managed to get a little bit done today, but not much. I got the exhauste manifolds disconnected from the exhaust pipes. Also got some of the plumbing and wiring disconnected. Everything is going slowly but surely.

11/01 2003: Well, I haven't done anything all week since I've been at my mom's house, and my trucks at my dad's. Good news though, I just bought a C6 transmission and a New Process 208 (NP208) transfer-case for $200, so that is definately going to help things out for me, and I don't have to pay for any adapters, yay!!. Thanks to das_jeepinator from http://www.Pirate4x4.com

11/03 2003: Disconnected the fuel lines from the fuel filter. I managed to drink some gasoline while I was at it. YUCK!!!

11/04 2003: I had to work on the ranger a bit today, so I could get some parts out that I am selling. I removed the slave cylinder and the clutch master cylinder, which won't be needed since I am switching to an automatic transmission. I also attempted to disconnect the driveshafts from the transfer case, but the bolts were frozen. I ended up PB Blasting everything 3 times, and gave up for the night, so it could soak. I was also able to drain the transfer case fluid.

11/05 2003: Disconnected the rear DS from the t-case. Attempted to get front DS disconnected, but failed.

11/06 2003: Ended up cutting the bolts to disconnect the front DS from the front axle. I also FINALLY!! got the t-case pulled. After the DS came out, the t-case was a piece of cake.

11/07 2003: The day is still in progress. Sold the t-case to Will, from TRS (The Ranger Station). Thanks man!! Well, I ended up being lazy and not doing anything.

11/08 2003: IT'S OUT!!!!!!! Finally got the 302 pulled out of the van. Ended up pulling the transmission and driveshaft as well. When pulling the engine,I had to remove the upper intake manifold and throttle body to allow for clearance when pulling it out.

11/09 2003: Cleaned up in the barn a bit more today, mainly so we have a clean place to finish up. We also barely managed to get both the ranger and the van in the barn. We moved them both in there, so I can finish getting the wiring, computer, fuel lines, fuel pumps and both sending units out, while getting started on pulling the 2.8 out of the truck.

11/14 2003: I got the truck titled today.

11/17 2003: I took the hood off. I also disconnected the battery and removed it. Then I took out the air intake stuff. I also drained the oil as well.

11/18 2003: Drained and pulled the radiator today. I also started disconnecting the wires, and I got most of it disconnected.

11/19 2003: I made a lot of progress today. I completely finished removing all of the wiring. I also pulled off the carbuerator, and disconnected the exhaust. The problem with the exhaust, was that the bolts were completely frozen, and the impact couldn't even get it off. I ended up cutting and beating the crap out of the exhuast pipe with an air cut-off tool, and an air hammer. All that's really left before pulling it, is disconnecting the tranny bolts, and then the motor mounts.

10/20 2003: IT'S OUT!!!!!!!! I finally got the 2.8 out of the ranger. The cool thing is, I did all of the work myself, without the help of my dad, and I pulled it myself!!! The tranny is still in, but that will come out soon.

Here's some much better shots, especially now that I have a digital camera. I apologize about all of the previous crappy pictures.

12/01 2003: I started studying the wiring system in the van, and trying to figure out how to remove the main wiring harness. Only worked for about a half hour before my Dad got home, and told me to come in the house.

12/02 2003: Started to try and disconnect the main wiring harness from under the dash. Ended up quiting because I had so much homework to do.

12/03 2003: I had planned for this to be the day that I get the wiring harness out, and possibly the computer as well, but I had to meet my Dad and Stepmom on the other side of the city, and ended up not having a chance to work on it at all.

12/04 2003: The wiring harness is being a PITA to get out, so NO I haven't gotten the stupid thing out yet.

12/05 2003: Messed around some more, trying to get the harness disconnected. I gave up in frustration.

12/07 2003: Removed the computer and all of the wiring harness on the passenger side of the engine bay. I still only have to get the other side disconnected. I also attempted to get the tranny out of the truck, but the bolts are frozen. I need to pick up another can of PB Blaster.

12/10 2003: Pulled the connection in the harness all the way through the firewall, but I can still not disconnect it. I'm about to completely cut up the firewall, and remove all of the dash wiring as well, and keep it connected and swap it all into the ranger. I also attempted to remove the bolts holding the tranny in the ranger, to the tranny cross member. The bolts are frozen in place. Gave them a good soaking in PB Blaster, and gave up for the day.

12/16 2003: Today Dad and I pulled the tranny out of the truck finally. We had to remove it with the cross member at the same time. We also had to cut off the exhaust pipe about a foot behind the cat, to make it easier for the tranny to come out, because of the cross member.

Before

After

12/19 2003: Started removing all of the wiring in the engine bay. Couldn't get the main harness out though, because it is connected under the dash. Since that was the case, I started to unbolt the bench seat in the cab, just so I can have a whole lot easier time messing around under the dash. I couldn't finish because Dad called me in for supper and told me to quit for the night.

12/21 2003: Dad and I started tearing into the dash on the van after pulling the driver side seat. We're going to try and remove the entire wiring harness (main engine and dash) and put it the ranger, and probably use all of the guages and stuff from the van. I'm not entirely sure how I am going to do that yet, but I will get a better idea once I start tearing into the truck dash as well. We also pulled the brake master cylinder and brake booster. Going to hope that they will both fit in place on the ranger.

12/22 2003: Pulled the second seat out of the van. Also got the bench seat out of the ranger out. Pulled up all of the floor covering. AHH!!! On the floor where your feet would normally rest, was almost completely rusted through. Uh oh. Time to figure out how I am going to fix that.

12/23 2003: Started tearing into the dash in the truck. I need to get all of the dash wiring harness out so I can put in the van harness.

12/24 2003: Merry Christmas Eve everybody!!! Yes, I am still busting my butt on the truck the day before Christmas, but I have to get this thing done. Anyway..... I'm still tearing into the dash on the truck. I made a lot more progress today though. Got the EEC (Computer) out, and that let me pull all of the engine harness completely out all the way to the driver's side at the dash. In the dash, however, I pulled out the heating vents, and then I pulled the gauges out. I also took off the steering wheel cause it was bugging the heck out of me. Hopefully I can get almost all the rest of the wiring out either friday, or early next week. I also pulled out the electric fan that was in the engine bay, and then I pulled the brake booster and brake master cylinder.
I also got my new motor mounts from Advance Adapters today!!! Christmas present from my Dad and Step Mom. They also gave me a truck tool box, which will go on my 2wd Ranger for now, until I am done working on this Ranger.

12/29 2003: Today I pulled the complete wiring harness out of the truck. Main engine harness and dash harness. Had to cut the wires where they met at the dash in order to pull it out though. I tried fitting the van radiator, in hopes that it would fit. Well, it was quite a bit too big. I think I'm going to try and go with a bed mounted radiator, tranny cooler, and oil cooler. I'll need to get a larger electric fan though. I also pulled the motor mounts off of the truck. I then put the new AA mounts onto the V8 block, just to make sure that they fit.

12/30 2003: Didn't do too much today. Mainly started cleaning up the frame a bit with a wire brush connected to an electric drill. Only did the frame in the engine bay for now. I then started to pull the rear bumper off, so I can attempt to remove the bed again, but a buddy of mine stopped by and I ended up distracted so I didn't get much done there. Had to go inside then. Slow day today.

12/31 2003: Tried getting the bed off again. It's hard to believe that I am having so much trouble, but if those clips hadn't broke, it would have been off 3 weeks ago. Just need to wait for dad to come out and give me a hand. Got pissed of because I couldn't get it off, so I started to clean up the frame a bit more to calm my anger, hehe. I'm picking up the suspension kit and axles tomorrow!!!

1/01-1/02 2004: Went to Terre Haute today to pick up a 6 inch suspension lift, front and rear stock ranger axles and 35x10.5 BFG AT's, but the guy still didn't have the rear axle out of the truck yet. Ended up just hanging out with my step-brother and his friends for these two days. I'm kinda pissed that I went all the way out and came home with nothing.

1/04 2004: Finally got the bed off today. Had to cut the heads off of three of the bolts and then we were able to pull it off without any problems.

I have to add this picture in, much to his dismay, if you can't tell. This is my Dad, who is my biggest supporter on this project, and the biggest help. He can't wait till I get it done, so he can drive it a bit, lol.

1/12 2004: Started cleaning up the frame a bit under the bed. Decided I better remove the gas tanks to make cleaning a little easier.

1/14 2004: Pulled all of the fuel hoses and pump and wiring out. I also cleaned up most of the frame with a wire brush on a drill. I also finally cut the last couple of bolts off, that was holding the rear driveshaft on.

1/15 2004: Went to work on the van again today. I decided to give the truck a break, and it was nice and sunny out so I figured I better try and get some more wiring out of the van. I've run into a problem of not knowing where some of the wiring leads to when it goes up the passenger side A-pillar, beneath the sheet metal. I don't know if it's something that is important or not. I will try and trace where it leads to tomorrow.

1/16 2004: Well, I finally got the wiring completely out of the van. Had to cut the wires at the firewall, but that was the only way it would come out. It's going to suck soldering all of those wires back together. When I finally got done with that, I started disconnecting brake lines on the truck. They are all so rusted that I am going to take them all out, and then buy I set of tubing and bend and fit my own brake lines.

1/26 2004: Removed the pedal assembly from the truck today. I figured I better get the pedal assembly stuff worked out under the dash before I start putting the wiring in. I was going to try and use the whole van pedal assembly, but it was too large. I had to remove the pedal's off of each assembly, and then shorten the shaft for the van pedal, in order for it to fit properly in the assembly from the truck. I also cleaned up the assembly just a tad.

1/27 2004: Today I installed the brake pedal assembly. I then started to install the main engine wiring harness. I have run into a couple of small problems. Since the harness is out of a van, it is a little bit shorter so it might not fit properly when connected to the motor. I also installed the computer, but I am not sure how I am going to mount it yet. I don't really have much room, and the wiring is pretty stiff, so it's hard to move it around. The only wiring that is actually hooked up, is the computer, and for the heater and blower motor. I also managed to untangle the mess of wires and am starting to mount them on the sidewall in the engine bay.

1/28 2004: Today I finished bolting the solenoid and a couple of other things for the main engine harness to the passenger side sidewall. I then started to dash harness in. I got it in and then tried to figure out what went where.

1/29 2004: Today I tried to figure out some more of the in dash harness. I finally figured out how I am going to match all of the wires for the steering column with the harness from the van. I realized that they are both color coded the same. There will just be a few that I don't need because of different locations for the wiper washer stuff between the van and the truck.

1/30 2004: It was FREEEEZING COOOOOOLD today. I couldn't spend too much time working on the truck, or else I would freeze. I did, however, get the wiring spliced together for the steering column, which is good, so now I can start putting the dash back together for sure.

1/31 2004: Today I extended the wiring for the wiper motor. I also the tried figuring how I am going to a do the guage cluster. I will also need a longer speedo cable, probably from a full size truck.

2/01 2004: Today, my Dad and I pulled the torque converter and flywheel off the 302. We were going to try and fit it in, but figured it to be too much of a hassle and did some measuring instead.

2/05 2004: Pulled the valve covers off the 302 and took them to the golf course so I could bead blast them and clean them up. Didn't have enough time to finish them and Carlos said he would finish them for me.

2/24 2004: I haven't done much for a looong time. I'm extremely low on money right now so I can't do too much more, because of the few things that I still need before I go much farther. Today, I tried to figure out the wiring some more for the windshield wiper motor and controls. I think I have an idea of what to do, but I will have to look at it some more.

2/25 2004: Well, I think I figured out how I am going to wire the truck wiper motor with the van wiring harness. I started connecting wires but I ran out of the connectors so I will have to pick up more connectors after school tomorrow.

2/26 2004: I went and bought more connector's, and started wiring up the wiper motor. WELLLLL, I ran into the problem of not knowing where to hook up the black wire (don't think it's ground).

3/09 2004: This time I have definately figured the wiring out for the wiper motor, and have that last wire to hook up and I am good to go. I have a job interview tomorrow, so I might have a chance to start making some money, so I can get this thing finished. I CAN"T WAIT!!

3/10 2004: Today, I complete the wiring for the wiper motor and reinstalled it in the truck. I then went to the van and started studying the rear axle. It turns out that it will cost waaay too much to be able to swap it into the ranger. I don't want to have to cut it down so it will fit.

3/11 2004: Today, I removed the front gas tank out of the van and removed some of the wiring and fuel lines off of the frame.

3/16 2004: Prepped the valve covers for priming. Then I put 3 coats of engine primer on and 1 coat of High Temp Engine Pain in Ford blue.

3/17 2004: Did some minor paint repairs on the valve covers.

3/18 2004: Completed painting of the valve covers.

3/23 2004: Pulled the rear tank out of the van. I also started pulling the fuel lines and wiring off the frame but ended up stripping a few bolt heads and got extremely pissed off so I gave up for the night. I also got a new driveshaft, t-case skid plate, and tranny crossmember in the mail today!

3/27 2004: Worked on replacing the distributer cap, rotor, spark plugs and wires.

3/28 2004: Pulled the truck out of the barn today for it's first bit of sunlight in a loooong time. Unfortunately it wasn't under her own power. I had to power wash the frame in hopes of getting some loose rust off, so I can start spraying the frame with rust killer, and then prime and paint it. I will have several pictures up sometime, but I am having problems uploading the pictures onto the computer so it might be a while. I also ordered some more parts through Summit Racing.

3/29 2004: Today, I sprayed the frame with the permatex rust killer stuff. It needs about one more coat, and it should be ready for primer. I removed both exhaust manifolds today, and cleaned the block up a little bit. I then reinstalled the valve covers. I bought a new serpentine belt today as well, but still need to install it. I am waiting on a few more things and then the motor will be ready to go in. Dad and I also put the truck back in the barn today, and without the boat in there, there is plenty of room to work on the truck.

3/31 2004: Today was a good and bad day. Bad part is, Napa ordered the wrong flexplate AGAIN, so now I have to wait till Friday for the proper one to come in. Good part is, Summit sent me my B&M Light Truck Megashifter, my Summit Oil Filter Relocation Kit, and my header gaskets!! They delivered right on time, and I would recommend Summit Racing to anybody who might ask!! Ok, now on to what I did today. I primered the entire frame of the truck, and started to fit the 5.0 Explorer headers onto the block. I ran into a problem with the location of some coolant lines. So, as long as the flexplate gets in friday morning, I hope to have the stupid motor sitting in the truck.

4/01 2004: Today I sprayed undercoating on the frame instead of painting it. I figured the undercoating will last much longer than the paint would. I didn't get too much else done unfortunately.

4/02 2004: Today I installed the flywheel and am still bolting up the headers. Hehe, yea, I'm being slow about it.

4/04 2004: Today, I completed getting the headers on.

4/05 2004: Today, I installed the oil filter relocation kit.

4/06 2004: Today, I installed the torque converter. I then prepped the floor and moved everything out of the way so that I can put the motor in tomorrow (knock on wood)

4/07 2004: YAY!!! We finally got the motor in the truck. It's not bolted down or anything, but at least it is sitting in the truck. We ran into a problem with trying to manuver the valve cover around the heater box.

4/08 2004: Today I tried manuvering the motor around without pulling the heater box and was successful at getting the valve covers to slide around the heater box. The only problem I have run into know is the motor is not wanting to go back far enough so that the bolt holes for the motor mounts will line up. It's getting there slowly but surely. I also replaced the turn signal which I bought from 88mnranger on TRS.

4/09 2004: Today, I tried manuevering the motor into place with no avail.

4/10 2004: Today, after pulling the motor completely out again, we were finally able to get it bolted down!! We had to pull the motor out because the motor mounts were not aligned properly. We switched sides with the motor mounts, and had to redrill a hole about 1-1/2" back on the passenger side in order to get it to fit properly. It was a pain in the butt, but it is in and secured down finally.

4/11 2004: Today we realized that the motor was cocked to the side a little bit, and the motor mounts weren't sitting completely down in the hole, so we had to pull the motor again. We redrilled the holes a little bit lower, and went back to the orginal hole we had drilled on the passenger side. Once we got it back, it lined up perfectly. We then started to install the tranny and t-case. we got them up and between the frame rails, and the tranny in put shaft is through the output hole in the torque converter, but it is not mounted to the block yet, and there is no cross member. The t-case is going to be a very close fit, but unlike what I have been told about the NP208, I just might be able to get it in without having to cut out too much of the frame, if any.

5/04 2004: Started cleaning the intake out, but ran out of cleaner. I then reinstalled the pulleys on the front of the engine.

5/05 2004: Today, I pulled the fuel lines out of the van finally. I also finished cleaning up the intake, and set it on the motor. Turns out, I'm missing 2 of the 6 bolts, AND the hood won't be able to close because it sticks up too far. EDIT: I later noticed that I didn't have the manifold seated properly, so there is a little more clearance available.

5/07 2004: Today, I pulled the rear axle out of the van to sell to Tom Campbell from RRORC. As I was removing the axle, the jackstands holding the van up, shifted, and collapsed and the van fell on my hip. Thankfully I was alright thanks to two of my friends who were helping me out.

6/19 2004: Well, haven't update in quite some time, but I have done a little bit of work. Mainly been working on my axles which you can see on Page 8. I did finally get the tranny and t-case bolted up properly and I just have to get the xmember in still. Hopefully I can get some of the wiring done today.

6/25 2004: Finally got the rest of the bolts I needed and installed the upper intake manifold. Throttle body went on as well, and was able to get some of the wiring connected and run across the engine the way I want it. I also temporarily installed the semi flex fan just to get an idea of spacing for the radiator.

6/26 2004: Today got the belt back on, and that was the main engine stuff I did.

Well, it's been 2 months or so since I've actually updated this thing, especially with pictures... I'll let you guys figure out where I am at, at this point.