The more I think about the truck, the more I start losing sleep trying to come up with a plan. One of the things weighing on my mind is the engine. I replaced the original motor back in 2014 with one from a 1996 Ford Explorer. I have no idea how many miles are on the engine, but I know Bobby said it has a leak at the cylinder head. I haven't been reunited with it it. I plan to go out and tear in to it this spring.
Other than being stock, the motor has a Jet Performance Module and Borla exhaust.
I'm throwing around some engine ideas, and I know there are expenses that aren't listed, but I'm trying to get some idea of options and cost.:
Rebuild / Overhaul Option #1:
Engine Gasket Kit: Sealed Power Engine Kit Gasket Set 2601699 - $114
Rocker Arms: Melling Rocker Arms MR-927 - $99.00 ($8.25 each)
Timing Set: Sealed Power KT4028S timing set - $67.00
Stock Replacement Pushrods: Sealed Power RP3332 - $57.00 ($4.75 each) (5.48")
Oil pump: Melling: M128 Oil Pump $70.00
Oil Pump Pickup Tube: Melling 345S Oil Pump Pickup Tube $46.00
Total = $453.00 (assuming all of the rocker arms are replaced)
Rebuild / Overhaul Option #2:
Replacement Cylinder Heads - $500-$600 (pair)
Engine Gasket Kit: Sealed Power Engine Kit Gasket Set 2601699 - $114
Timing Set: Sealed Power KT4028S timing set - $67.00
Stock Replacement Pushrods: Sealed Power RP3332 - $57.00 ($4.75 each) (5.48")
Oil pump: Melling: M128 Oil Pump $70.00
Oil Pump Pickup Tube: Melling 345S Oil Pump Pickup Tube $46.00
Total = $854.00 (Replacement heads)
Rebuild Upgrade #1:
Comp Cams 49-410-8 camshaft - $295.00
Smith Bros NH54A-DD 5.550" Pushrods - $144.00 ($11.95 each)
Rocker Arms: Melling Rocker Arms MR-927 - $99.00 ($8.25 each)
Engine Gasket Kit: Sealed Power Engine Kit Gasket Set 2601699 - $114
Timing Set: Sealed Power KT4028S timing set - $67.00
Oil pump: Melling: M128 Oil Pump $70.00
Oil Pump Pickup Tube: Melling 345S Oil Pump Pickup Tube $46.00
Total = $835.00 (Rebuilt factory heads & camshaft upgrade)
Rebuild Upgrade #2:
Replacement Cylinder Heads - $500-$600 (pair)
Comp Cams 49-422-8 (or 410) camshaft - $295.00
Comp Cams 988-12 Dual Valve Spring - $67.00 (set of 12)
Comp Cams CCA-775-16 Spring Retainers - $55.00 (set)
Smith Bros NH54A-DD 5.550" Pushrods - $144.00 ($11.95 each)
Engine Gasket Kit: Sealed Power Engine Kit Gasket Set 2601699 - $114.00
Oil pump: Melling: M128 Oil Pump $70.00
Oil Pump Pickup Tube: Melling 345S Oil Pump Pickup Tube $46.00
Timing Set: Sealed Power KT4028S timing set - $67.00
Total = $1,357 - $1,457 (Replacement heads with upgraded camshaft)
Explorer 5.0L Swap:
Engine & Trans - $500-$600
BW4406 Transfer Case - $200
Cylinder Head Gasket Kit - $60.00
Oil Pump - $31.00
Timing Chain Set - $35.00
Timing Cover Gasket Set - $14.00
Crank Seals - $14.00
Oil Pan Gasket - $16.00
Total = $870-$970
Here's a really good deal on an engine donor:
https://tuscarawas.craigslist.org/cto/d/new-philadelphia-ford-explorer-awd-675/6803625136.html
This assumes that the engine is in good mechanical condition and just needs freshened up with gaskets, seals, oil pump, and timing set. This doesn't include motor mounts and all the other things that might be needed?
Will also need some driveshaft mods.
I know some of you may think you should just replace everything with a V8. I've been very please with the performance of the 4.0L. I've had a 302 Ranger 4x4, and they're great for throwing mud, so I know the benefits of a V8. I want a reliable truck that I can travel all across the country in.
Anyone have any advise as to why I shouldn't just overhaul the 4.0L in it now??