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Old 12-25-2009, 07:22 AM   #1
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Cool 5.4 32valve "BOSS" swap

Well, it isnt going in a Focus BUT I'm getting geared up to do the "BOSS" swap with my 96 Mystic Cobra.

For those that Dont know the BOSS swap is taking out the 4.6 32 valve and putting in a 5.4 32 valve.

I recently located a 5.4 4v motor (THANK YOU Mike) that already has the 8 bolt Forged crank in it and the large port heads. While at Hillbish picking up the motor I managed to snag a FordRacing FR500 head rebuild kit for cheap... complete with 32 valves, 32 high lift springs, retainers,gaskets ect.

Current plans are to tear down the motor, get it "freshened up"

Full P&P on the heads with some "custom work" done as well
.030 flat top pistons (~11:1cr)
ACE forged steel rods (good for 1000hp)
rebalance the crank
Stage 4 crower cams (or maybe a set of custom cams)
aluminum flywheel, MMR clutch kit
40# injectors
custom long tube headers
Possibly looking at using a GT290 intake off of a Ford Falcon (Austrailian branch of Ford)

I'm hoping to make between 400 and 500whp... I'll be happy with 450whp which is a reasonable goal. If I dont make the power I want then I'll go with plan B...... Big Ass WHIPPLE!!!!


Some of you are wondering why forged steel rods.... 2 reasons

1) they weigh about the same as forged aluminum
2) half the cost of forged aluminum (plus stronger)

I'm sure I've left some stuff out but oh well for now.

There will be pics and some vids in the coming weeks (more likely next week)

Disassembly "should" start next week and I'm going to do the motor before I pull the old one out (which runs perfect).

At least this should be a fun project.


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Old 12-25-2009, 09:19 AM   #2
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Wow sounds like a nice swap. I need to get a car that I can learn more on.
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Old 12-25-2009, 11:01 AM   #3
I need BOOOOST!!!!!!
 
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so whats the plan exactly? you going to keep the 4.6 as a backup just in case or ya gonna get rid of it? and i might be a little young to get it or maby im just not good and awake yet but what is a big ass whipple? S/C?
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Old 12-25-2009, 11:19 AM   #4
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yup. badass s/c lol.

if you're not using that 4.6 can I have it? lol jk I think ill stick with a reliable engine. lol.

sounds fun though! ill hopefully be rebuilding a failboat mazda so I can start mine
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Old 12-25-2009, 01:32 PM   #5
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You guys do know that Ford Austrailia has been using the 5.4 32v motor as their "top of the line" performance motor for years dont you??

It'll be very reliable, and as a bonus when people ask what I have under the hood I'll just say 32v 4.6..... since the only differences are the 5.4 is about 1.5 inches taller and about 2 inches wider... most people will never even notice that.
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Old 12-25-2009, 01:33 PM   #6
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I'm going to keep the 4.6 for a little bit, then most likely I'll part it out.... especially since it is a Teksid blocked 4.6
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Old 12-25-2009, 01:52 PM   #7
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So if you put down 450whp, you think it would be a close race between it and the Slowcus, or would it pull hard? That is a fair power gap. I think it would be a cool race!

Good luck, should be no sweat for you. Trying to get my turbo kit on next week
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Old 12-25-2009, 01:56 PM   #8
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Look at it like this, the 5.4 has tremendous bottom end umph.... it should be around 350+wtq at 2000rpm..... plus I plan on spinning it to at least 7k.

Good luck on the install!!!
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Old 12-25-2009, 06:06 PM   #9
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It was go to see you guys Jon. I guess ill see ya again when youre down to Toms later.
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Old 12-25-2009, 06:15 PM   #10
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Oh I BELIEVE it will be reliable lol. I mean there's gotta be way cheaper aftermarket good stuff for a 302 than a 4.6 or 5.4 right? LOL.
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