jEEd

np man, good luck to you whenever you start your swap, feel free to ask me if you encounter any problems or if you have any question!

5spd GT

[quote]ORIGINAL: jEEd

here is everything you'll ever need to know about the whole swap! i've done it so if you come across any problems, don't hesitate to ask me.

1996-1998 Mustang GT 4.6L – Installing 2001-2004 Romeo Heads/Cam/Intake for PI Head Swap

Parts Checklist:

01+ PI Romeo Heads with Cams – 1W7Z-6049-AA (RH) and 1W7Z-6049-AA (LH) (1 each)
01+ PI Intake Manifold Assembly – 1W7Z-9424-AB – (1 assembly)
99+ PI Cams - 1L2Z-6250-AA (RH) and 1L2Z-6250-DA (LH) - (1 each)
01+ PI Head Gaskets – 4C2Z-6051-AA (RH) and 4C2Z-6051-BA (LH) – (1 each)
01+ PI Intake Gasket – YL3Z-9439-BA -(1 each for a total of 2) – or Fel Pro – MS-92121
01+ Cam/Valve Cover Gaskets – F6AZ-6584-AA (RH) and F6AZ-6584-BA (LH) – (1 each)
New OEM Head Bolts – 5R3Z-6065-AA -(20 bolts)
Alternator Bracket - F8AZ-10153-EA – 96-98 with PI Intake/Al. Crossover - (1 bracket)
Coolant Tube – XR3Z-18B402-AA - (1 tube)
Coolant Nipple – F75Z-8555-AA – (1 nipple)
Timing Cover/Front Cover Gasket – F1AZ-6020-A – (1 gasket)
Timing Cover/Front Cover Gasket – F1AZ-6020-C – (1 gasket)
Timing Cover/Front Cover Gasket – F6AZ-6020-BB – (1 gasket)
Exhaust Manifold Gaskets – YC2Z-9448-A - (4 gaskets)
Crankshaft Seal – F5AZ-6700-A – (1 seal)
Crankshaft Bolt – F5RZ-6A340-B aka: F1AZ-6A340-A – (1 bolt) or ARP-156-2501
Camshaft Bolts – YF7Z-6279-AA - (1 for each cam for a total of 2 bolts/10mm bolts)
OEM Dipstick or Lokar Oil Dipstick - XR3Z-6754-BA or LOK-ED-5014 – (1 dipstick)
Upper Plenum O-Ring – XR3Z-9L437-BA – (1 o-ring)
Thermostat O-Ring – F1VY-8255-A – (1 o-ring)
Water Pump O-Ring – F1VY-8507-A – (1 o-ring)
Header Down-Pipe Gasket – XR3Z-9450-AA – (1 gasket)
Stock or 180* Thermostat – 3L3Z-8575-AC (192*) or XL3Z-8575-AA (180*) - (1 t-stat)
Spark Plug Wires – F8PZ-12259-HA – (1 kit) – You do not need the wires, it is just an extra.
Spark Plugs – SP-505 – (8 plugs): Motorcraft AGSF-22C's gapped at .048 to .050 for normal street use or AWSFA-12C's for street/strip. The 12C's are 2 steps colder than stock and if you are going to run it hard it might be a better option.

1996-1998 Mustang GT 4.6L – Installing 1999-2000 Windsor Heads/Cam/Intake for PI Headswap

Parts Checklist:

99-00 PI Windsor Heads – 2L1Z-6049-DA (bare) and complete is 2L3Z-6049-BA (RH) and 2L3Z-6049-DA (LH) - (1 of each)
99+ PI Cams - 1L2Z-6250-AA (RH) and 1L2Z-6250-DA (LH) - (1 each)
01+ PI Intake Manifold Assembly – 1W7Z-9424-AB – (1 assembly)
99-00 PI Head Gaskets - FC2Z-6051-AA – (RH) and 4C2Z-6051-BA – (LH) – (1 each)
99-00 Intake Manifold Gasket - YL3Z-9429-BA - (1 each for a total of 2)
Cam/Valve Cover - 2L3Z-6582-BA and 2L3Z-6582-DA - (1 each)
Cam/Valve Cover Gasket - 2L3Z-6584-AA (LH) and 2L3Z-6584-BA (RH) – (1 each)
Cam/Valve Cover Bolts – Need 27 new/used windsor valve cover bolts/grommets.*
Windsor Head Bolts - 3L3Z-6065-AA - (20 bolts)
Alternator Bracket - F8AZ-10153-EA – 96-98 with PI Intake/Al. Crossover - (1 bracket)
Coolant Tube - XR3Z-18B402-AA - (1 tube)
Coolant Nipple - F75Z-8555-AA - (1 nipple)
Timing Cover/Front Cover Gasket - F1AZ-6020-A - (1 gasket)
Timing Cover/Front Cover Gasket - F6AZ-6020-BB - (1 gasket)
Timing Cover/Front Cover Gasket - F1AZ-6020-C - (1 gasket)
Exhaust Manifold Gaskets - YC2Z-9448-CA (4 gaskets)
Crankshaft Seal - F5AZ-6700-A – (1 seal)
Crankshaft Bolt – F5RZ-6A340-B aka: F1AZ-6A340-A – (1 bolt) or ARP-156-2501
Oil Dipstick or Lokar Oil Dipstick - XR3Z-6754-BA or LOK-ED-5014 (1 dipstick)
Upper Plenum O-Ring - XR3Z-9L437-BA - (1 o-ring)
Thermostat O-Ring - F1VY-8255-A - (1 o-ring)
Water Pump O-Ring - F1VY-8507-A- (1 o-ring)
Timing Cover Bolt - N808142-S437 – M10 - (Comes in Pack of 4, washers included)
Timing Cover Stud - N808140-S309 - M10 - (Comes in Pack of 4, washers included)
Timing Cover Stud - N808529-S309 -M10X1 5X1 - (Comes in Pack of 4)
Header Down-Pipe Gasket – XR3Z-9450-AA – (1 gasket)
Stock or 180* Thermostat – 3L3Z-8575-AC (192*) or XL3Z-8575-AA (180*)- (1 t-stat)
Spark Plug Wires – F8PZ-12259-HA – (1 kit)
Spark Plugs – SP-505 – 192* (8 plugs): Motorcraft AGSF-22C's gapped at .048 to .050 for normal street use or AWSFA-12C's for street/strip. The 12C's are 2 steps colder than stock and if you are going to run it hard it might be a better option.

* - Windsor valve cover bolts come with grommets that attach to the windsor bolts and Romeo valve cover bolts are separate from the grommets.

Ford Head Changing Kit – Applies for 96-04 Heads:

The head changing kit can save you some money. It includes head gaskets (older gen. 7 style), head bolts, exhaust manifold gaskets, oil dipstick tube, and head bolt bushings that help you install the heads in the engine bay. It keeps the head bolts from protruding past the bottom of the head while installing. Easily removed and easier to use. Keep in mind, the oil dipstick tube that comes with this kit does not line up to the head bracket area, but it can work in a pinch with some customizing. I had no issues with it. It is part number FMS-M-6067-D46 for a little over $100.

Parkway Performance 2V Headswap Complete Kit:

This kit is nice if you do not want to piece together the parts, but you may pay a bit more for the kit, than piecing it together.

More Windsor Head Swap Information:

Windsor Heads/Valve Covers has 13 (driver side) and 14 bolts (passenger side), and Romeo has 11 bolts.

If using Windsor heads (99-00), you will need 99-00 Valve Covers and extra valve cover bolts, Four 10mm bolts and 4 10mm studs (Romeos need 8mm) that put the timing cover to the head for a total of 8 with 4 on each side. Drill out heater tube bracket at the back of the head and get bigger bolt (10mm x 1.5 and 20/25mm) to hold down the bracket.

If you want to piece together the extra timing cover bolts and studs, here are the sizes:

(A) 5 long double studs (10x1.5 thread both studs, 18mm Hex) that go into the top 4 holes of the T.C. and 1 goes in the outside lower Driver side.

(B) 1 shorter double stud (10x1.5 / 6x1.00 thread, 18mm hex) that goes in the Pass. side outside lower hole.

(C) 2 Standard Timing Cover bolts (10x1.5 thread, 13mm hex) these go in the inside lower holes of both banks.

Windsor heads have separate cam journals and Romeo heads have two bridge style caps.

Windsor cam gears are press fit and not bolt-on like 96-98 and 01-04.

Chain guide differences in Romeo and Windsor:

The left bank chain guide has a minor difference. The early Romeo guides use two bolts in the cylinder head for the upper mount and a dowel in the block for the lower locator. The Windsor engines use 1 bolt in the head and one bolt in the block. The right bank Windsor head will have two holes in the head so it's a direct bolt in on that side. The left side, however will only have one bolt hole in the head so you'll be using 1 bolt and 1 dowel on the left bank if you use the original Romeo guides.

In other words, it will work fine either way.

Extra Parts If Needed:

ARP Camshaft Sprocket Bolt: ARP-256-1001 – 12mm x 1.5
12mm Camshaft/Crankshaft Bolt for 96-98 and aftermarket camshafts- F5RZ-6A340-B aka: F1AZ-6A340-A - M12-1.5 (1 for each cam for a total of 2).
ARP Harmonic Balancer Bolt w/washer: ARP-156-2501
ARP Head Stud 12 Pt Kit: ARP-156-4301 – Fits all 4.6/5.4/2V/4V complete with nuts/washers.
ARP Head Stud Hex Kit: ARP-156-4101 – Fits all 4.6/5.4/2V/4V complete with nuts/washers.
Cam Spacer - F3AZ-6265-A
Cam Washer - F1AZ-6278-A
Romeo Cam Gears - F8AZ-6258-

96GT226410

Nothing was implied about him writing itand who cares if you wrote it up? There are a bunch of places where you can get the same list. What's so special about "your list?" If you didn't want it online then you shouldn't have posted it. Is it registered to you? Does he have to edit into the post you as a referance? Ha ha... [8D]

96GT226410

I reconditioned a set of heads for a guy on a different forum. He was doing a PI swap, too. I can take the heads apart in about 20 minutes from fully assembled. I have a hot tank in my shop and I let them run through for a whole day. I rebuilt them in about an hour and had them back to him the next day at lunch. Easiest $150 I ever made.

*Edit for picture:

It looks like intimidating, but it's real easy...

jEEd

looks good :] well done!

5spd GT

You obviously do not know who I am.

Nowhere in the post was it posted that someone had written it or supplied it. I have already talked to jEEd about this and he handled it very well.

Now, I could care less if someone post that "I" did it. Just make sure it was not implied, and give credit to someone else. Again, I repeat, one does not even to mention my handle. I could care less.

It is common courtesy to give credit where credit is due. Even with only 1,7XX post, I figured you would realize this.

It is registered to me as a matter of fact.

No need to post me as a reference, just let people know that someone else did it.

That list is the most comprehensive one, minus pictures, I have seen.

I have been there and done that for a few PI Headswaps. If you are ever my way, and need help, I'm more than capable of handling the swap.

Good Luck in all your future endevours.

fr8flyer

I have a question about the parts list, why does it list 4 cams if you're using the 01+ Romeo heads? The parts list says 01+ Romeo heads with cams (LH & RH)and then two items down it lists 99+ cams (LH & RH). If you're using the 01+ Romeo heads you can't use the cams? Do you replace them with the 99+ cams?

5spd GT

The 99+ cams are interchangeable and can be used on any year model head (99-00 or 01-04)

The top Romeo block list has a part number for complete heads (that includes cams).

A couple spaces down I have the individual cam numbers, in case you already have heads (minus the cams).

The second Windsor block list has a part number for bare heads (doesn't matter, because they can be RH or LH before cams are installed). On that same line, it includes a part number for the Windsor heads assembled with the cams already on them.

The next line down on the Windsor list, are just individual cam part numbers, in case you already have heads (minus the cams).

96GT226410

Wow, ok then...