92 4.0 v6 engine replacement

[rrengineer]

My 92 XL lost its cool (cracked head or head gasket) and pretty much trashed its insides (bearings, pushrods and rocker arms and probably mains as well). I have been told that I need to stick with a 91 or 92 engine in order to remain plug-n-play. Is this true or can I use most any Ford 4.0 v6 motor?

 

[GenerationX]

Have you seen this yet? It looks like it may help you out with that question. It talks about some of the calibration having to do with the different cams, heads & pistons that came with the OHV.Dead Link Removed

 

[rrengineer]

Thanks for the web site. The information is very interesting and has lead me to think that buying a junk yard replacement is not in my best interest. For that matter, buying another 4.0 v6 is not really a good choice at all. Too bad the v8 swap is so expensive.

 

[Big E]

One thing I looked for when I put the second engine in my Explorer was the warranty of the replacement engine. I know Marshall engines carry a 75k or 3 year warranty. Not sure if it covers labor or not but I installed it myself, and if it ever went bad I can lift with pulling the engine out and swaping it for free.

Just a idea if you decide to keeps the 4.0.


Eric

 

[rwest!]

Engine Replacement

Reeng,

I had to get a 'new' engine for my '92 Eddie Bauer in January and I had to decide weather to purchase a rebuilit for $2000 or take the chance to have rebuilt - my mechanic found one from a '94 Explorer that at 67,000 miles on it and for $925.

My truck runs better now then it ever did. You may want to look around for a engine from a different year too - that's just my suggestion.

 

[rrengineer]

Big E, I checked out the Marshall's motors at Dead Link Removed and am waiting for them to return my quote with a price. Their 3 year/100k mile quarantee is hard to beat.

rwest!, I have also looked into junk yard motors and that is where I learned that not every year will work in every vehicle. But like you, the price is hard to pass up on.

The website posted by gearlo40 at Dead Link Removed is worth reading.

Thanks for all your help. It is all greatly appreciated.

 

[rrengineer]

Sorry guys, I fat fingered the url for Marshalls. It is http://www.marshallengines.com/

 

[410Fortune]

After 93 the heads are of a stronger casting.

After 95 the compression goes from 9:1 to 10:1

You can use any OHV 4.0L engine, you just have to be careful of a few things.

In 91 & 92 the OHV 4.0L had a single 02 sensor, in 93 they have two.

Look for an engine equipped with EGR if you have EGR.

Also you will notice that your 91-92 has a MAP sensor, the later years do not.

So it's just a matter of using your exisint wiring harness and possibly bolting some of the stuff from your engine onto the new donor (EGR for example)

There are some differences after 94 as well, most of them are cosmetic and to the layout under the hood....

Up until 97 (I believe) the basic OHV (underneath all the plastic garbage) is the same.

 

[Ross-N-Chicago]

I have been contemplating a rebuild or a new engine (remanufactured) and found this place that for the price is tough to beat reconditionedengines.com

I'm all ears to experienced voices out there but when my engine finally quits this is what I'm doing. Fuel injectors and some other things as well. How in the world will the exhaust manifold come off after 10 years?!?! Will Liq Wrench penetrate that much??

 

[rrengineer]

I figured that the header bolts would break. But then the old heads go with the long block so it would be someone elses problem. Not that I would intentionally snap the bolts off, just that trying to loosen them, even with copious amounts of WD-40, does not seem to work.