I don't know where you are getting this high numbers from.
Replacing timing chain guides are nowhere near that expensive if you do it yourself. I think the best timing kit was maybe $300, the camshaft alignment tool is $200. It's mostly time and effort. About two days worth of work if you pull the engine ($180 engine hoist. $50 engine stand, and a case of beer for your friends
). If you wanted to be adventurous you could do the front and rears with the engine in the truck after you pull the transmission
. The transmission will be expensive, but you can get a rebuild or reman ones for about $2000.
Been driving and working on Explorers for almost 12 years.They have their problems, but do the basic maintenance (and run synthetic and a Motorcraft oil filter in your SOHC) they will last a long time. Even when I bent two rods in my V8 the thing still ran (was still running when I tore it down). I think the biggest issues on the 1st and 2nd gens (more 2nd gen) is fuel pumps, lower intake gaskets on the OHV's, and transmisions (Excluding the 4R70W in the V8's, but the A4LD's are just awful in the 1st gens without a Frankentranny rebuild).
Okay - I'm rebuilding my Job 2 4.0 SOHC engine. I made a list of everything I need to buy to do the job usin(g what I consider to be the best available parts. Many of the parts I'm using are Motorcraft. They are expensive. TTY bolts, timing chain kit, new harmonic balancer to name a few. I will also be buying Felpro upper and lower engine gasket kits, which are not cheap. I will need an OTC 6488 cam installation tool (between $200 pre-owned and $260 new. My cylinder heads will need to be machined and tested. I may need to replace the crank/rod bearings. I plan to install a new oil pump. The list goes on and on and it all adds up. This is bearing in mind I already have most of the required tools, multiple floor jacks and jack stands, an engine hoist with an equalizer and an engine stand. For this job I also decided to replace my cheap foot pound 1/2 torque wrench with a quality, more accurate one and to buy a quality inch pound torque wrench instead of using my 3/8 foot pound torque wrench. My estimated total cost of my engine rebuild will be around $2000-$2500. Could I buy a reman engine for about the same money? Yes, but I don't trust anyone else to work on my engine and I want to use what I consider the best parts available. Many engine re-manufactures don't even change TC components if they think they're still okay. You can buy cheap timing chain kits for about $60 on eBay. The last time Iooked the Motorcraft TC kits were around $560. For that difference in cost there has to be a difference in quality, even considering Ford parts tend to be ridiculously expensive and that the real issue is the plastic pieces get brittle and eventually break.
As far as rebuilding my old transmission... This is something I've never done. Maybe I could accomplish it, but after watching several YouTube 5r55e tear-downs IDK that this is something I want to try. A full trans rebuild, or reman, is around $2000-$2500 in my area (and they come with a warranty).
I guess if I wanted to do everything based strictly on lowest cost I could get the cost of an engine and trans rebuild down quite a bit, but I plan to do this job once and to do it right. If I fail I want it to be because I f'd up, not because I bought a cheap part. It's just the way I do things.
Below is a list of everything I could think of I needed to buy to rebuild my engine:
Tools Needed:
Torx e-socket set for exhaust header studs
Metric crows feet set for P/S hoses
27mm wrench for EGR nut on header
Valve spring compressor to remove/install cam followers
OTC 6488 cam service set/timing tool
T55 1/2" drive torx socket to remove/install head bolts
6 point 29mm socket to hold crank shaft (maybe)
New digital ft pound torque wench
New inch pound torque wrench
Parts Needed:
Felpro head bolt sets (2)
Felpro MLS head gaskets
Felpro upper engine gasket/seal set
Felpro lower engine gasket/seal set
Full Motorcraft timing chain set
Front and rear tensioner metal gaskets (maybe)
New TTY harmonic balance bolt
New front and rear TTY cam shaft bolts
New TTY jack shaft bolts
New TTY connecting rod bolts
New oil pump
New Motorcraft fuel injector adapters/seals
New or reconditioned fuel injectors
Rear engine jack shaft seal/plug
New harmonic balancer
STD crank/rod bearing sets (maybe?)
Evaluate and mill heads & grind valves
New Motorcraft oil pressure switch
New P/S high pressure hose
New W/P (?)
New W/P bypass hose
New heater hoses?
Simmions aluminum t-stat housing for ST
Insta-Lube pre-oiler kit
Miscellaneous Needed:
Blue Loctite
Assembly lube
Ultra Black RTV
5 qts 5w30 Mobil-1 full syn engine oil
2 qts Mercon 5 for P/S
Motorcraft FL820S Oil filter
Antifreeze
New group 65 battery