Swapping engine in an E-Series-how difficult?

[Marauder_Pilot]

So my new-to-me '05 E-350 Clydesdale came to me with a blown cylinder. Specifically, cylinder 7, likely leaned out by a stuck fuel injector, which is apparently a noted problem on Ford 5.4L engines of that era. So, long story short, she's getting a new engine

That being said, how difficult is it to swap the engine on an E-Series? Obviously because the compartment is so tight, it'll be tricky, but I'm definitely willing to learn, and have the space to do it. However, I've never done anything as in-depth as an engine swap before either, although I can probably enlist help from people who have. As it stands, I'm looking at about $4000-$5000 for my mechanic to drop in a replacement engine, and half of that is labour. Is it worth taking on this project myself, or should I leave it to the professionals for the moment?

 

[Mwilliamshs]

Smooth concrete floor in a 20x20 shop should be considered mandatory if you have the $ for the mechanic. Otherwise you'll regret not laying out for the labor. If the weather's not bad an open carport can work but you'll want at least the width to put the cherry picker next to the van (reach in from passenger's side) and a roof. Other than space, a hoist (can rent one if need be), and hand tools, this is very doable. You'll need a couple specialty tools but most parts stores loan them.

I say go for it. This is a great way to get to know your rig and you can apply the experiential knowledge top everything that comes along.

 

[Marauder_Pilot]

Yeah, I have access to an enclosed shop and an engine crane, so working space isn't my biggest hurdle.

Is there any particular scares I need to be on the lookout for? I browsed some guides online, and they all looked fairly straightforward-basically just take everything off the front of the van, unbolt the engine and slide it out, but that sounds suspiciously simple (Definitely not EASY, obviously, but straightforward ), then just do the whole thing in reverse with the new engine.

 

[ujoint]

If the van has little to no interior then yanking the body is always the best way. But, need a lift for that.

The engine can come out the front and should be pretty easy on a 5.4. I've done diesels like this and the 5.4 is much smaller. Going out the pass side door is not possible, just unbolt the core support and remove the radiator, plenty of room.

 

[Mwilliamshs]

...Going out the pass side door is not possible, just unbolt the core support and remove the radiator, plenty of room.

I'd trust Chris on this. My experience is on older rigs.

 

[Marauder_Pilot]

If the van has little to no interior then yanking the body is always the best way. But, need a lift for that.

At the moment, the van's interior is stock-less than stock actually, since all I got to before getting a diagnostic on the engine was rip out the seats and some interior panels. But I don't think I can get ahold of a hoist that can lift the body up. I can get ahold of a bunch of bottle jacks and some wood, though! However, height of the shop may be an issue too.

Relative to how much of a pain in the *** lifting the body off would be, is it worth the hassle of rigging up a hoist? I've never lifted the body off a vehicle before.

 

[gtbensley]

I would say not worth it to lift the body unless you have a lift. Pull the front support and take it out that way.

 

[ujoint]

I agree, if you don't have a lift its not worth it.

 

[Marauder_Pilot]

Alright, going out the front it is. I've decided I'm going to give it hell. I'm going to be away at school, and have a ton of free time, for the next two months anyways, and the shop I have to work on it is literally next door to my mechanic's shop, so what's the worst that could happen?