Ford 1999 V-10 swap to a Ford 2000 V-10

Good day...
We (my wife and I) are going to install a 2000 Ford V-10 engine from a 2000 Motorhome (20,000 Miles Motor Home was broad sided on Passengers side) into our utility Truck..
1999 F-250 Super duty, V-10 2 WD Auto, club cab ,short box.

My concern is...
The 2000 V-10 Engine NEVER had an Exhaust recirculating tube from the left exhaust manifold. The inner Intake housing is a PLASATIC/something composite construction.

The 1999 V-10 Engine has an Aluminum inner Intake manifold and an Exhaust recirculating tube from the left exhaust manifold.

I have purchased all of the GASKETS so as we can swap the two Intake manifolds and left exhaust manifold.

I'm concerned that if we do not do the Manifold swaps, the Exhaust gases may deteriorate the Plastic /composite inner intake manifold.

Manifold pics off Intrnet.
I'm quite aware that the entire fuel RAIL assembly/Injectors fuel pressure reg. shall be swapped from the 2000 to the 1999

Thoughts on the above ..
Thanks
Bob..

You are right to be concerned, in the 90s Buick's 3.8 V6 had EGR through a plastic intake manifold, the manifolds degraded resulting in a coolant leak into the manifold. Buick released a new manifold that was also plastic that was supposed to be the fix. I installed the new manifold and then traded the car.

No answers other than our 2001 F350 5.4 has no egr, burned up a coil driver output on the computer. Picked up a computer from a junked US truck of same year, was good for a couple of months until it completed enough drive cycles and started throwing all kinds of permanent EGR monitor codes and ran like garbage. Found out the US computer expected there to be an EGR system to run.

Recently found a non-egr computer for it, haven't tried yet at the starter seized while parked.

My vote would be to set it up without EGR.

Swap the parts use all new exhaust mounting hardware parts stores are way cheaper that OEM ford.

I kept looking for the oil cooler I see it now replace all those problematic gaskets also. Make sure the spark plugs will tighten up.

There is also a coolant pipe and a adapter that goes in the block behind the water pump under the intake I have seen those rust out.

This post was edited by Hobo,NC on 02/18/2022 at 09:33 am.

I agree you are doing the right thing. I suspect that the tube from the exhaust manifold has an EGR valve that controls when and how much gas gets recirculated and that is controlled by the PCM. With input to that valve missing and the expected change in the exiting exhaust gases measured by an oxygen sensor you would always have a dash warning light on and a code.

What would be wrong with avoiding 'mix & match', by using the engine as is along with the matching engine control computer/module?

Reckon you could plumb a J-79 in there? Plenty of power;-)
Your method seems like it should work, Best Wishes. Sometimes Ford's better idea has a hidden surprise or three :-(.

Quote:
Reckon you could plumb a J-79 in there? Plenty of power;-)
Your method seems like it should work, Best Wishes. Sometimes Ford's better idea has a hidden surprise or three :-(.

Now you have my attention MF#1..........
Bob

Use the original manifolds to keep EGR, replace all exhaust studs even if they didn't break, replace oil cooler above the filter, check all sensors to make sure they are the same connection and in the proper locations, make sure the heater hose connections are in the right spot. The oil pans might be different too.

1999 and earlier v10 heads are different than 2000-up. The change was for improved flow and increased power. It's possible the split happened mid year of 1999. The later heads were call "PI heads" PI stands for power improved, early heads are referred as NPI or non-PI. The casting number just above the front exh port will tell you what you have. NPI will have "6.8L W", PI will have 6.8L PI". Another way if you have the intake off is the comparing the intake ports and coolant passages, they are noticeable different and not interchangeable

I don't know if the motor coach followed the same dates on PI/NPI heads, so the above paragraph might be moot. Also the early V10's had a split on intake gasket design. The int ports are the same but the later gaskets have alignment tabs on the gaskets. If your heads appear the same, you might verify your gaskets match the ports and alignemt tabs have a spot to sit in.

This is starting to look like fun... The Emission gods sure throw a monkey wrench into swaps : (... Good info...

Thank you 4play.
Bob..

Thank you JMOR....
I shall check to see what the DIFF. ratio is, and if the Transmission had or has a specific computerized shift logic...

Bob

Thank you used red MN

Bob..

Thank you Hobo,NC

Bob..

Thank you, Ken Macfarlane
Bob..

Thank you RCP

Bob..