302 blocks , which one?

Okay long story short
Replaced rear main seal ( professionally) , leaks month later
Very angry

I'm looking at new blocks, I have a pretty much stock 99 5.0 (gt40p heads )
The rear main seal has driven me mad, mad enough to change the whole block in order to get a non leaking seal , needless to say the ford racing 302 blocks are looking pretty good , my only problem is I need a good understanding there are so many 302s on there with numbers like 4 inch bore or rough 4.115 what ever
I understand that is cylinder size ?
How do I go about matching up all these ?
I have a lot of questions and plan on doing this engine right all help is appreciated

 

[JamesRolls5.0]

To any mods : The reason I posted in need for speed is because I'd like to do this 302 fairly up as well, but if it more appropriate in another section I understand , thanks

 

[Turdle]

Ok, sweet. What are your expectations of the truck?

How much horsepower do you want to achieve?

 

[JamesRolls5.0]

Smoke da other kid
Lol no in all seriousness , I'd like to hit 400 hp or so
I do plan on keeping it for a DD but this is what I weighted , if I build this up nicely I'll have a pretty much new truck (no rust , did custom exhaust and massive overhaul on suspenion n etc already)
I've fallen in love with my truck and a new engine would mean like having a new truck (transmission is strong but on the list)
My starting budget is 2.5 k but my 18 birthday is tomorrow n I'm looking for a cash injection ;D

 

[rjcooperss396]

Really, you're going to build a new engine because of a rear main seal leak. What seal did the shop use? I just built a 347 and used a teflon seal which is supposed to be better than the rubber ones. It started leaking after about 400 miles. I replaced it with a rubber one and so far with 2500 miles it doesn't leak. So unless the seal leak is just an excuse to build a new engine I'd start with checking the seal.

 

[JamesRolls5.0]

Not about to lie to you , it's an excuse
I was told they used a rubber one as well, I personally think they prolly screwed me over , had a friend go there over something n his truck ended up with more issues , I just don't wanna go through the process of dropping the tranny or removing the engine , re doing a seal myself n then have it leak because the ring or crank is tweaked

 

[vroomzoomboom]

hate to tell you, but if your looking for 400hp and budgeting for 2500, your not going to get far. the reason i say this is headers will run around $700 ish mark. heads (if you go alum) will be $1500-2000 mark. stroker kit without machining $1500 mark. to give you an example, i just finished doing a explorer express m90 supercharger kit (which is no longer in production, and lucked out finding one used) and the final tally on it with supporting mods was around the $2000 mark, and i know i am no where near 400hp.

 

[JamesRolls5.0]

oh no im very aware of the full cost ive been reading threads all night with ideas, im starting this with what i have on hand, this is going to be an all summer project, 2500 is what im starting with for a good block and internals, anything left over moves on to the next items budget but just saying 2500 is not my entire budget

 

[Turdle]

for 400 hp allow about 10k, because this isn't a mustang and most parts will not fit. I doubt even the torquemonster headers will flow 400 hp without the help of a bottle or blower of some sort--

Good luck. If a rear main seal is your stumbling block you have a lot of work and frustration ahead of you.

 

[JamesRolls5.0]

i understand or at least i think i do and idk the rear main seal has just always hit a nerve with me , ive been dying to do something with this truck since i got it, is 400 hp even a realistic goal ?
ive seen 3 400+ hp 302s from friends cars , things were, they weren't in an explorer

more importantly, ive always though hp when cars, but once again its an explorer, should a goal be a torque number instead?