1997 XLT 4.0L SOHC Overhaul

[eric425]

Our Explorer has been in our family since we drove it (brand new) off the lot in 1997. Recently one of the timing cassettes failed.
Our explorer is the 1997 XLT 4.0L SOHC model. She's one of our favorite cars. We're definitely not going to give up on her.

The explorer has 287k miles so I figured I would go through it a bit more than just simply installing new timing cassettes. I took the heads off and took them to a local machine shop to be cleaned and checked if they require a skim. I am using all Ford parts for the engine. I have all new seals, gaskets, and all the required ford timing components.

I was planning on leaving the block alone but since the engine has almost 290k miles I've been thinking I might as well install new bearings and see if the cylinders need a hone with a fresh set of rings. One of the issues I've come across is the connecting rod bolts are TTY. I have not seen any available online. The only way I can see to get those bolts is to buy 6 new connecting rods... I did see on this forum that another user ran the ARP 154-6002 connecting rod bolts. Has anyone else used those ARP bolts without any issues? Any tips for the rebuild would be greatly appreciated! I'd be happy to post some pictures if you guys want to see the progress.

Cheers!
-Eric

 

[wollimann]

I am using all Ford parts for the engine. I have all new seals, gaskets, and all the required ford timing components.

This is a good starting point with OEM parts, i leave the block alone while doing the timing job, no bearings no hone.
So i can not say anything about the ARP bolts. I had problems to get the bolts for the cams (left and right thread) and the balancer bolt.
I bought the OTC tool box set, new oil pump, valve rod seals, manually grinding-in the all valves cause of pitting, new crank seals, new injectors, cleaned the hydrolic lifters, cleaned the oil pickup for plastic parts. With the Ford manual it should be a manageable job, exept pulling the engine, exhaust bolts and motor mount nuts, everything rusty.
If it is the 4x4 SOHC it has the balance shaft which must have 7 rotations to align with the first piston on top.
If you pull the upper oilpan, while reinstalling it the rear (engine and pan) must be very flush.
I am only an engaged private mechanic, but the job was done and the engine runs with its 186k (300000 km) miles.
Whish i have had the money to get new heads, new pistons and new bearings and a maschine shop hone job.
In Europe it's not very nice to get this old baby on the road as an daily driver.
All the best for your project, all thumbs up!

 

[eric425]

Thank you for your input on the overhaul! I found all the required seals, gaskets, and components needed for reassembly. Except for those connecting rod bolts. I don't think I'm going to buy all new connecting rods just for those bolts. I'm going to use the ARP connecting rod bolts for reassembly. I'm going to ask the machine shop what they think about them as well. ARP makes quality components so I believe they should work just fine. My explorer is the 4x2 model so I don't have to worry about the balance shaft. But thank you for that information about the balance shaft. I'm sure aligning the balance shaft via the rotations could be overlooked. I also bought the timing tool kit and the rear main seal installer tool as well. I like your thinking! I also bought a new Ford oil pump, front cover, and a new water pump. I also bought new valve seals. I'm having the machine shop check the valve guides for me. I still need to clean the lifters. Some of the lifters are very hard to remove from the head. Most of them came right out of the head easily. But a few seem like they're stuck. The machine shop said they can get those out for me. I live on the west coast here in the US, so luckily I don't have too much rust. I have the ford manual so I'm doing everything just as the manual specifies. I'm glad you got your explorer back up and running! That's awesome!

Here are some pictures of the disassembly. I found all the pieces of the plastic cassette guide that broke. I pieced them together like a puzzle to ensure I got them all. The new front cassette guide I bought from Ford looks different than the original guide. I'm assuming the guide was redesigned. But I am not sure on that.

Thanks again for your input!

-Eric

 

[C420sailor]

Consider going with mechanical tensioners and you’ll never have to worry about that engine again