2004 Explorer Engine Replacement Cost

[NickXLT]

Hey all, I have a 2004 Ford Explorer XLT with a 4.0 V6 for 204k miles. I got it from my grandparents at 142k with no problems, around 160-170k it started making the infamous timing chain rattle noise. I have put it off for far too long, so I am in the process of figuring out just how much it will cost to replace/rebuild. I am 99% sure it is the timing chain, only happens when I got above 2,000rpm and cold starts can sound a little scary at times.

I have already replaced the transmission at 189k, but otherwise this thing runs like a champ. I just want to see what the ballpark is that I would be paying for this job to be done. I move to college in a few months and I don't feel like having this hanging over me while I am there. Any and all suggestions are more than welcome.

 

[410Fortune]

Where is the noise? Front of engine or back?

The timing cassettes and tensioners can be replaced in the truck on the front

The back the engine must come out

 

[NickXLT]

I'm pretty certain it is the back of the engine. I am not 100% sure, but even if it was the front cassette, I would want the rear replaced so I don't have to worry about that breaking. Do you think it is worth it to replace to just replace the cassettes, tensioners, and chains? Or at that point do I just do a replacement/rebuild.
I would like to replace all the rubber hoses as well, some of them have seen better days.

 

[410Fortune]

Sohc engines are very tough
Their weak spot is the timing chains guides and tensioners
With a good running sohc that is just noisy, usually we can get away with pulling the engine and doing a “refresh”

This would be a full tear down and rebuilding all new gaskets, tune up parts, oil pump, and all timing components

That is all they usually need
However a compression test before pulling the engine is the way to determine if you can re use your engine or not

Many of us can do this sort of thing in a 5-7 day timeframe given the parts are here and tools available. If it’s your first time pulling an engine and re stabbing it then it can take longer

Cost anywhere between $800-2000 depending on parts used

 

[Number4]

The guides can be broken and not make a sound. Then, seemingly out of no where, poof, the engine is shot.

If you have an engine stand, cherry picker and some time, this is a job you can do yourself.

 

[ss1019]

I have a 2004 Explorer with the 4.0 and at 205K it broke a piston ring land. I put a used engine in it and while it was out I did the chains and cassettes. I was quoted almost 40 hours labor to remove and replace the motor and "refresh" with heads rebuilt and short block piston and rings and bearings. At their labor rate of $85 per hour (lower than most) it would've been $3500 in labor alone. Total was expected to be around $6K. The used motor cost me $2K and it had 90K miles. The chains and cassettes were still good but I changed them anyway since it was out. I did the engine r&r myself and around $250 in parts. I didn't replace all of the hoses but did the major cooland hoses and the water pump and t-stat. I probably wouldn't do it again. They are easy to buy the whole vehicle running for less.