I have a 4.6 from a 2003 Explorer (2v) and I am wondering if it's the same block as the other 4.6 modular engines? Aside from heads, manifold, and internals, is there any difference in the core block from year to year, model to model?

I tried to research it, but all I found was that the 4.6 modular has been built since 1993, and has been in a ton of vehicles.

If the core block is the same as in the 3v, I now have a core to start my long term engine build project.. If not, then I have some aluminum to recycle..

 

No, the physical dimensions are the same. Materials used and quality can differ but 4.6 is a 4.6 all parts are interchangeable hence them being called "modular"

 

So far in my research I have determined that A) Ford parts guys are no help whatsoever, and B) There are about 6 different castings of the 4.6 liter modular aluminum block since 1991.

The term "Modular" refers to the tooling process rather than the engine parts. They can rapidly change the modular tool system to produce different blocks and heads. I learned some really great stuff when researching this, but what I didn't learn is whether the 2003-2005 4.6 2v from an Explorer is the same block as the 4.6 3v that is in the 2005-2009 mustangs. I need to tear this engine apart and find the casting number, and try to find the casting number on a 3v to see if they are the same. If anything, it just might require a slightly different main or something.. shouldn't be a big deal.

Thanks for the help!

 

If you're talking about castings then yes there are tons of different ones from a plain old iron casting to a bullet proof Teksid bock. I misunderstood and thought you were talking about physical dimensions and holes for brackets and hardware. Anyway I'm 99% sure the Explorer block is also aluminum.