Here is the manual for a Ford 302 into a 240. Every swap is different. Lots of things you cannot avoid spending money on. A thousand is a very aggressive objective even with an engine and transmission in hand.
Nice to see you still post around on TB Tom! Ive read every bit of your swap and used it as somewhat of a guide. Lucikly the 7/9 cars are easier to swap a ford V8 in. Only slight massaging of the passenger side firewall is needed. I retained the factory ford explorer tubular manifolds and auto trans. Using a mustang radiator and electric fan.
So far i have
175 in custom driveshaft and balancing
300 in new gaskets and oil pan, new starter (preventive maintenance), plugs and wires, oil pump, water pump and stat.
11 dollars for new volvo solid mounts, retained volvo transmission mount.
85 dollars for a new mustang radiator, i had the electric fan from a crown victoria already.
40 bucks for new heater hoses, upper and lower coolant hose.
Just ordered another 100 dollars in misc parts and fittings to make up the fuel lines from the volvo m14 to ford quick disconnect and the ac fittings. I have a ac hose crimper tool so it saves me a few bucks there too.
I have a y pipe, just need to connect the downpipes to my 3in exhaust from when it was upgraded as part of the turbo upgrades.
I have my standalone harness built, retained pats and purge functions. waiting for my fuse block to show up to finish it up and decide where to stick the Ford ecu without having to extend that section of the harness.
My last volvo wagon had a factory locker in the rear. This turbo wagon seems like its an open diff when i spin it in the air and when ive driven it on the road. I havent decided if i want to swap in the explorer 8.8 in after having the one side narrowed. Still thinking about that one.
Still a rear main is much easier and cheaper than a motor swap. After blowing up 2 B230ft's and having this v8 powertrain i was ready to make the move.