About to do a PI headswap, got a few questions

[Pete@FTR]

Hey guys, found a good deal on heads/cams/intake manifold off an 01 gt for $200, going to buy it now and do the swap into my '96 in a few weeks once I graduate. I found this http://www.beaterswap.com/headswap/ writeup and read through it, but I still have a few questions:

1. Do i need to change the valve covers for PI covers?
2. Is there a link to a good pi headswap walkthrough?
3. Is it worth it to have a machine shop resurface the heads?
4. Also has anyone ported their PI heads and how much did you pay/what performance gains did you see?

Thanks!

 

[cobraracer46]

I would advise to clean up the cylinder heads and resurface them only if they need it. Putting pi heads on your car will raise the compression to 10:1 and cutting the heads will jack up the compression even more.

Get a head changing kit from Ford Racing.

Read this TSB as well:

ENGINE—NEW GASKET REMOVER/CLEANER ANDSERVICE TIPS FOR ALUMINUM HEADS ANDBLOCKS
FORD: 1992-1997 THUNDERBIRD
1992-2002 ESCORT, MUSTANG, TAURUS1992-2003 CROWN VICTORIA
1995-2000 CONTOUR
2000-2002 FOCUS
2002 THUNDERBIRD
1995-2002 WINDSTAR
1997-2002 E SERIES, EXPLORER, F-1501997-2003 EXPEDITION
1999-2002 SUPER DUTY F SERIES2000-2002 EXCURSION
2001-2002 ESCAPE

Article No.02-11-4

LINCOLN:
MERCURY:

1992-2002 CONTINENTAL1992-2003 TOWN CAR2000-2002 LS
1998-2003 NAVIGATOR2002 BLACKWOOD
1992-1997 COUGAR1992-1999 TRACER1992-2002 SABLE
1992-2003 GRAND MARQUIS1995-2000 MYSTIQUE1999-2002 COUGAR1993-2002 VILLAGER1997-2002 MOUNTAINEER


ISSUE

properly as designed. In this scenario, a gasket or
RTV bead will only act as a “compression” gasket,which is insufficient to seal the area. Preparing thesurface with the products listed herein will leave aclean, dry surface in which new replacement gasketcan bond with the metal.
SERVICE INFORMATION
“Motorcraft Silicone Gasket Remover” (Motorcraftpart number, ZC-30) is a softening and looseningagent which attacks RTV and residue left behind bya multi-layered steel gasket. It is packaged in apliable tube in gel form. It sits on the residuebuild-up breaking down the bond between the RTVand the metal by working in a more concentratedform.

Gasket removal, especially on multi-layered steel(MLS) head gaskets may leave behind a residuethat is difficult to remove from the sealing surface.Effectively immediately, two new cleaning productsare released to the field for use in removing gasketand oil residue from aluminum cylinder heads.These products are available and are recommendedwhenever a cylinder head is removed from theengine. The purpose of these cleaners is to ensurea safe cleaning process is available which will notthreaten the integrity of the sealing surface of thehead.
ACTION
If petroleum residues are left behind neither theMLS gasket nor RTV will adhere to metal and bond

Copyright © 2002 Ford Motor Company

PAGE 1

Article No. 02-11-4 Cont’d.

The second product which is used as a follow up tothe Gasket Remover is “Motorcraft Surface Prep”(Motorcraft part number, ZC-31) and is packaged ina small can with applicator brush. This is used as asurface preparation to rid the sealing area of oil,coolant residue and residual RTV before installingthe gasket and before RTV is applied to tee-joints.
Surface Cleaning And Preparation:
This is a crucial step in the success of a headgasket repair. The set-up time to soften RTV willvary, depending on the thickness of the residue leftbehind. Remove as much of the old material aspossible with a plastic or wooden scraper withoutdamaging the aluminum with score marks ordepressions. Coat the surface liberally withMotorcraft Silicone Gasket Remover (ZC-30). Allowthe softener to act on the remaining residue andremove it with plastic or wood scrapers only. Next,coat the surface with Motorcraft Metal Surface Prep(ZC-31), let sit for several minutes (depending onamount of residue) then wipe clean with a lint-freecloth. This will remove any remaining deposit orresidue and prepare the surface to receive RTV andthe MLS gasket.
Use of power sanding, grinding, and buffingequipment is unauthorized for warranty repairs. Useof manual grinding and scraping aids which includesandpaper, razor blades, or metal scrapers is notauthorized. Resurfacing of aluminum machinedhead gasket surfaces is also unauthorized for repairby Ford Motor Company.

Plastic or wood scrapers in conjunction with thenew gasket remover and surface preparationproducts identified in this bulletin are the onlyproducts allowed for servicing Ford aluminumcylinder heads.
For older engines using composite gaskets it isrecommended that a steam application (powersteam jenny or dip tank) be directed at the hardresidue.
This will re-hydrate the material and soften itsufficiently to use a plastic or wood scraper forremoval. It is still recommended to apply a coatingof ZC-31, Motorcraft Surface Metal Prep, to rid thesurface of all coolant and oil residue. RTV andsilicone bead gaskets will not bond to the surface ifthere is a film left behind.

PART NUMBER
ZC-30ZC-31

PART NAME
Motorcraft Silicone Gasket RemoverMotorcraft Metal Surface Prep

 

[96gtsleeper]

on getting the heads ported is what I imagine you refuring to they average at about $500. the valve covers work well as long the heads are not from a windsor block. then you would need the covers from those heads. The gasket I recommend either the head gasket changing kit from Ford Racing product, or the complete head gasket kit from felpro gasket. the advantage of the FRPP gasket set is you get the head bolts but no intake gaskets. With the Felpro set you get the intake gaskets but no head bolts.
I really recommend you get the heads resurfaced.
Also wanted to state that if you do get windsor heads you might have to change the eight upper timing cover bolts. differnt size.

 

[PWNY]

I did the PI head swap. I bought new PI heads/cams so I did not have them mechined. That might be a good idea to machine the heads to make sure they're not warped as long as they don't take too much off. Porting them would be worth the money seeing as you picked them up for so cheap. I used the Ford Racing head install kit. I also put in new timing chains/tensioners/guides. I was able to use the same valve covers on mine, no issues. My base dyno was 193hp-262ft/lbs...after head swap 242hp-283ft/lbs. You definitly feel it! And the higher compression sounds real good. I also have an SCT Xcal2 so I got a new tune for it.

 

[Cpotts13]

Alos... if you want longtubes now is the time.. while it is easiest.

 

[Ferocious]

Longtubes are a good idea, but seeing as you live in Cali I wouldn't advise doing it unless you can get around emissions.
And this is probably the most helpful guide to doing the swap imo:
http://mustangforums.com/forum/4-6l...st-pi-swap-write-up-all-you-need-to-know.html


And I would also recommend getting the car professionally tuned after if your money allows it.

 

[Burninrock24]

This is the best headswap write up I know of: http://www.allfordmustangs.com/forums/4-6l-tech/160636-pi-swap-write-up-1996-mustang-gt.html

Bring them to a machinist to see if they are within tolerance. If they are, then leave them be. If they aren't then get them milled back to the max tolerance and use a thicker gasket. These mod motors are way too picky with the tolerances that they like to be in.

Porting is iffy. The modular motors have a completely different porting strategy than what most head porters are used to with pushrod motors. So make sure that the porter has experience with mod heads before doing it.

Also, make sure to set aside money for a tune. You are changing pretty much every parameter that the stock tune is used to. Canned tunes won't compensate for the change either. So safely expect to pay $400-600 for Dyno time depending on if you own a tuner already