whitestang97

Can Someone give me a complete list of everything i need to do the swap...thanks

the only thing i have are the heads and intake

hpwrestler220

check the stickies

Chris98Gt

If you have a set of romeo heads all you need is head bolts, gaskets, intake, and ehaust gaskets. You will also need a pi coolant tube that fits around the deeper pi intake. If you have a set of windsor heads you will need a few new bolts/studs in the timing case cover. They are larger on windsor style heads.

whitestang97

pi coolant tube? hose that goes from the radiator to the engine? is that what ur talking about...and also i heard something bout a alternator braket and a heater hose and a dipstick...is all this really needed??

deej

first off, its not as hard as you think or looks, just take your time and you'll get it done

heres the write-up that i found after i did my whole swap but i found it very useful for all the specs n other resources

all credit of this write up goes to 5SPD GT as known on this forum and many other mustang forums.

[hr]
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, no cams) and with cams is 2L3Z-6049-BA (RH) and 2L3Z-6049-DA (LH) - (1 of each)
99+ PI Individual Cams - 1L2Z-6250-AA (RH) and 1L2Z-6250-DA (LH) - (1 each) - If you have camless heads.
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 – 4C3Z-6C519-AA (Pack of 4 bolt/grommets) - 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 Camsh

w8less

since when does post count actually matter

damn thats a lot of info

Sxynerd

YOu don't need anything for the PI Head swap because you should just swap out the NPI for a PI motor. Easier!!! I gained 81rwhp

96GT226410

If I were to do it again I'd swap out a whole motor. It's a lot easier.