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Re: comparing 4.6 to 5.4 litres
I think the 4.6L is a bit too small for the Expy.
I'd definitely get the later 3 valve 5.4L motor. I have the older (2004) 2 valve 5.4L and it's a pretty good engine, especially for towing. We get around 16-17mpg fwy running light and 13-14mpg towing & loaded. That's on crappy CA gas. I've seen as high as 19mpg fwy on New Mexico gas.
The later 3 valve 5.4L has variable valve timing which improves HP, torque, and mileage, it's a win win situation. I believe it's rated 2mpg better than the old one so you'd be looking at 15 - 19mpg realistically. Not bad.
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