Hello, I'm seriously considering this swap/swaps and was wondering what problems I will run into and what all will need changed. The engine swap will probably be later this year as the 5.2 in the van is still plugging along and I provably won't have time for an engine swap til then. I'd also want to tear down the 5.9 (360), clean everything up, measure the bores, check the heads, new rod and main bearings, oil pump, rings and/or pistons if needed, aftermarket cam, double roller timing set, Hughes plenum gasket repair kit (or Performer RPM Air Gap intake), etc. I'm guessing most of the sensors off my 5.2 will need to go on the 5.9 along with an older PCM.

 

"I'm guessing most of the sensors off my 5.2 will need to go on the 5.9 along with an older PCM."

My guess is about same. I'd suggest that if you don't get the answers you're looking for here in 2nd gen vans, then start a thread in 2nd gen trucks. Those guys in that forum are pretty active and helpful with projects like you are planning, lots of threads there on engine and transmission swaps.

 

Thank you. I posted in the 2nd gen forum as well. Sorry I logged in as my first username, gave the wrong email address and need to contact administration to fix that. - JC

 

You really would be better off finding a 1996 tranny unless a dealer parts department or salvage yard says a 2002 is a direct fit.