Getting prepared to do an engine and timing chains on a 4.0L

[2000StreetRod]

Potential surprises

There's always the potential of surprises when disassembling an engine of unknown history. I suspect the lower pan was previously removed as well as the front timing cover due to balance shaft chain rattle. Good thing you didn't install as is. I hope it was purchased for a good price. Examine the balance shaft chain closely for wear since it may have been striking the tensioner pivot post.

 

[WarriorDriver]

I removed everything as shown, saturday. The chain was working its way through that pin in the picture.

 

[WarriorDriver]

Here's a minimum list of parts for the 2002 assuming it has a balance shaft. Hopefully, I haven't forgotten anything.

TTY bolts that can't be reused:
Harmonic balancer retaining bolt. The harmonic balancer was changed for the 3rd generation so call Ford for correct part number.
The jackshaft front & rear sprocket retaining bolts aren't specified as TTY but are torqued as if they are.
Front 2L2Z6279AA
Rear W703167S430

Cover assy/rear of block jackshaft opening plug F77Z6026AB
Right/rear timing chain cassette assembly 4L2Z6M290AA
Left/front timing chain cassette assembly 7U3Z6A257A
Left timing chain spring/hydraulic tensioner 7U3Z6K254B
Tensioner metal O ring XU2Z6M252AA (optional)
Right timing chain tensioner 7U3Z6K254A
Tensioner metal O ring XU2Z6M252AA (optional)
Tensioner-engine jackshaft chain YL2Z6L266AA
Guide-engine jackshaft chain 2L2Z6K297AA
Gasket-cylinder/timing front cover 1L2Z6020AA
Gasket-upper oil pan/reinforcement section F77Z6710AA
Balance shaft chain tensioner 1L2Z6L266AA
Balance shaft chain guide F77Z6K297BC
Gaskets-intake manifold 3rd gen
Gaskets-exhaust manifold 3rd gen

If the right guide assembly is broken then you'll need the upper positioning bolt F77Z6U000BA

So, thoughts on whats all needed again after seeing the pics?

 

[2000StreetRod]

balance shaft chain

The balance shaft chain is not as robust as the other chains. Since it has been worn by striking the tensioner pivot I'd probably replace it.
Balance shaft chain F77Z6268BC
Right timing chain guide assembly upper positioning bolt F77Z6U000BA
I'd also replace the crankshaft rear seal. See Rear main seal removal and rear main seal replacement

 

[WarriorDriver]

cool, thanks!

 

[2000StreetRod]

block casting?

Please look for a block casting number. I think the 2nd generation block casting is 1L2E-6010.

 

[WarriorDriver]

Where is it located?

thought I got pics of all the numbers I could find

 

[2000StreetRod]

don't know

I was hoping you could find it and then tell me where it is since I don't know. I'll look thru all of the block photos I have available and see if I notice the number.

 

[2000StreetRod]

Mustang block

Below are photos of a Mustang block PN 5L2Z-6010-A but I don't see the same number anywhere on the block.

 

[WarriorDriver]

Found it!

 

[2000StreetRod]

1l2e6015a13a

Thanks! That confirms that the block did not change with the beginning of the 3rd generation. I think it changed around 2004.

 

[WarriorDriver]

ok, just sent this list to get a price check.

OTC 6488 Ford SOHC 4.0L V6 Cam Service Kit

Balance shaft chain F77Z6268BC

Right timing chain guide assembly upper positioning bolt F77Z6U000BA

Cover assy/rear of block jackshaft opening plug F77Z6026AB

Right/rear timing chain cassette assembly 4L2Z6M290AA

Left/front timing chain cassette assembly 7U3Z6A257A

Left timing chain spring/hydraulic tensioner 7U3Z6K254B

Tensioner metal O ring XU2Z6M252AA (optional)

Right timing chain tensioner 7U3Z6K254A

Tensioner metal O ring XU2Z6M252AA (optional)

Tensioner-engine jackshaft chain YL2Z6L266AA

Guide-engine jackshaft chain 2L2Z6K297AA

Gasket-cylinder/timing front cover 1L2Z6020AA

Gasket-upper oil pan/reinforcement section F77Z6710AA

Balance shaft chain tensioner 1L2Z6L266AA

Balance shaft chain guide F77Z6K297BC

Gaskets-intake manifold 3rd gen

Gaskets-exhaust manifold 3rd gen

Rear crankshaft seal

exhaust gaskets

water pump gasket

upper positioning bolt F77Z6U000BA

Also like to get plugs and wires for a tune up while its out

 

[WarriorDriver]

ack, ford dealer said theyd give me fleet pricing, and itll be $1275

 

[2000StreetRod]

Otc 6488

You can purchase a new OTC 6488 for $212 with free shipping on eBay: OTC 6488 Ford SOHC 4.0L V6 Cam Tool Kit . After using it you can usually sell it for $150.
Did you get prices for the OEM parts from Tasca?

 

[WarriorDriver]

These prices are from my local ford dealer, a buddy works there and said they would give me a discount, but pricing this stuff online, is cheaper without a discount. so far.

 

[WarriorDriver]

checking prices from tasca, still looking like itll be over $800 for parts... what can be reused? cant reuse sprockets or chains?

 

[2000StreetRod]

cassettes

The last time I checked the left and right guides were not available individually. You have to purchase the entire cassette (guide, sprockets & chain). I purchased a left guide a few years ago but it was NOS (new but old stock). I've said before the chains and sprockets can easily last 500K miles. Ford attempts to justify selling the guides as assemblies by arguing that wear pattern quickly develop on the sprocket/chain configuration.

Now you can appreciate why many SOHC V6 engines with bad guides are not repaired. The parts are fairly expensive, special tools and knowledge are required, and the process is labor intensive.

 

[WarriorDriver]

Ok, might use the sprockets over then, they look to be decent, even though two of them did rub on a bolt a little, or should I do those two chains? By not buying new sprockets, that saved a bunch. Need to order stuff up for this thing soon and get it together.

 

[WarriorDriver]

thoughts on cloyes kit?

CLOYES Part # 90701S

Or even

9-0398SB

Picture shows that kit has almost everything

 

[2000StreetRod]

good compromise

As I stated in post 5, I think Cloyes is a good compromise for cost vs quality compared to OEM.