Tnashua's 4.0 OHV rebuild... | Page 4 | Ford Explorer Forums - Serious Explorations

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Tnashua's 4.0 OHV rebuild...

Looks like mounting position is different on the 5.0 radiator & the upper hose is angled on the SOHC? I really want a 2 core- so which should I go with? If the post I found is right about the V8 radiator- it would sit 3/4" further forward?! If that interferes with the condenser- I could install longer bolts (& shims) to shim it back toward the engine (may have to move rubber mount pads too)... Can't find any other info on the SOHC radiator, but the picture shows the top fitting angled to the right (instead of straight out like mine out of the OHV). The brand I am looking at has both in a 2 core... The V8 one is about $15-20 cheaper most places... Anyone?
 



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Bought a radiator, got my bolts, took the engine back apart, installed the new rod bolts- discovered that the rod bolt installation shifted the caps enough that the rods need re-sized to maintain clearances... Machine shop is super busy- so it will be next week sometime before they get to them (I didn't even ask the price- I'm in so much trouble at home right now)- guess I won't have the X running by Saturday (found all of this out Tuesday)... Spent 1.5 days under the X grinding surface rust off of most surfaces I could get to (after I power washed all the grime away), spent another day priming & painting said places... Discovered that my VSS wires in the Rear Diff were sheared off at the plug- guess that is why I was getting that code all the time (maybe I don't need the VSS I bought after all). I was able to slice & splice to re-use the original plug... Been cleaning up engine compartment & components that didn't get cleaned earlier. Hopefully when the machine shop calls- I'll be ready for final assembly & installation...
 






Thats odd..never seen or heard of that happening. That sucks, least you caught it.
 






lots of small progress to document pictorially, but I'm too short on time- wanted to post this "fun" pict though... Kinda reminds me of a blown flathead :) (if you squint)...
10660240_891894294172457_2749937173034803212_n.jpg
 






I'll try to post better updates soon- Been way too busy lately.
I do want to say that the beast is up & running... I took it last weekend on a 250 mile excursion- it got 19.66 MPG :)
BUT- I seem to have a rear main seal leak?! I've had the intake & cooling system apart several times & removed the valve covers the other day because it looked like the pass side was leaking (had only sealed one side with permatex cause I was planning on swapping the push rods when the budget allowed)... Now that area seams dry, but still oily underneath. Really hoping that it had just pooled somewhere & dripped down when I drove it a little this morning, but I am doubtful... Anyone else have rear main seal issues on their rebuilt motors? I wasn't supposed to press the sleeve (that the rear main seal came on) onto the rear flange was I?! I assumed it was only there to avoid seal damage during installation... Any other ideas?! Help...
 






I didn't seal my oil pan gasket well enough on mine. That's a possibility for you also.
 






Sorry that I haven't been on here for a while... Still don't have much time! Wanted to give a brief update.

I've gotten about 1200 miles on the X since the rebuild...

The Bad:
I still have a slow oil leak from somewhere in the rear. It occurs to me that the crank flange probably was drilled all the way through & that I did NOT put any form of sealer on my flywheel bolts :( I haven't got the time or the patience to pull the engine or drop the tranny right now- so it'll keep the underside of the X lubricated until I find time (or the condition worsens and forces me to make time).

The Good:
No check engine lights, plenty of power from 1800rpm on up (curious what it'll do with a trailer behind it, but I have to get a hitch installed first), sounds decent for a V6, has been getting pretty good MPG considering how it gets driven (14-15 semi-agressive intown, 16-17 mixed, 18-20 Loaded Highway).

I lowered the front recently by relieving tension on the torsion bars. Think that if I can't find time next spring to fab up a coil over conversion- I'm at least going to find a set of code 1 bars to swap in to increase stiffness a bit. My Hellwig Rear Sway Bar just arrived today. I hope that it tightens up the rear (reduces rock/rollover)! I did some bartering for some 18's hoping they would fit, but determined that I'll need 2" spacers to make them work & they're probably stick out of the wheel wells- so I'm keeping my eyes open for a different set for next summer. I'd like to drop the rear about an inch and the front another half an inch or so. I haven't adjusted my camber on the front from my previous drop- need to get that done... Was hoping this mod would help MPG in addition to making the stance look more aggressive. Haven't filled up yet- so I don't know its affect yet...

Overall I am pretty happy with the performance of the engine- it is a beast... Just wish that I had gotten everything sealed up so that I didn't have to worry about checking the oil all the time! The heater core diverter valve is still weeping too (on account of my modified cooling system routing creating too much flow for the valve to handle?!), but that too is a very slow leak for now. I may make a CAI for it next summer to see if any more power or MPG can be had... May upgrade the stock coil & wires too- time will tell. I'll probably complete the Brown Wire Mod I was reading about some time ago & if my summer budget allows- I may freshen up the rear with a limited slip / posi unit (I get a lot of single wheel spin until the 4wd kicks in & I rocket).
Thanks for your support on this build... You can bet that I'll be back on here when next I have questions! For now- I need to get my Escort wagon project (as seen on FEOA) back on the road & try to patch up my marriage. Wish me luck!
 






Quick update:
Got a hitch installed- X pulls great! :)
Put a larger dia. sway bar & new HD shocks on the rear- vast improvement... :)
Been playing around with torsion bars- gained a little MPG when I dropped the front, but didn't adjust the alignment and was tearing up the inside of the tires- so I "jacked" it back up for the winter... Really want to pursue a coil over set up for the front.
Bought a load leveling/bag kit for the rear, but haven't gotten around to installing it.
Got pulled over twice in one weekend because the X was "too loud"- huh- never happened before- hasn't happened since... I love the exhaust sound (for a V6). :)
Best MPG I've gotten- 21.5... Average MPG seems to be between 18.5 & 19.5 (mixed driving) and around 16-17 for mostly in-town. That will likely drop with the nose back in the air and cold air around the corner...
Got the Scort going- and it was fun, but the marriage patching up didn't go so well & the Scort is in someone else's possession :(
Hope you are all doing well & enjoying your Explorers!
Till next visit...
 






Brief update:
Explorer has been a lot of fun & pretty reliable (barring an overheating episode brought on by a fried fan control relay while towing a camper in town), but it is time to tear back into things...
Clutch has been making more & more noise, Can't park the X on a hill because it won't stay put. :(
Starter gave up the ghost- so I parked it...
Been saving up some $$$ & collecting some parts for "phase 2".
Since I am going to be pulling things back apart- I've got a bearing & seal kit for the Transmission and a new flywheel.
Been pondering whether I should order any other Trans or Tranfercase parts. I really don't want to tear this thing apart again in my lifetime. I have done a fair amount of pulling (a camper & small utility trailers) w/ the X & it has done pretty well. Really think I should get an upgraded clutch to install though. Trouble is- I haven't found reliable info on the options out there. I've had great results with Centerforce DF clutches on hot rodded motors in the past, but the offering they have for my X costs over $400 and doesn't have the normal weight system... I've used LUK on stock applications & always liked their clutches... There are several "HD" clutch kits out there for a reasonable price, but I do not know their reputation. :( Any Suggestions?!
Thinking about pulling the motor back apart & going 75mm over with some 90-94 pistons to solve my perceived cylinder/compression issues & gain some CR. The X was still getting 18-19mpg mixed driving most of the time- so maybe it really is ok & I shouldn't mess with it. I still haven't received my compression tester from my other Ex- so I can't tell. Maybe the hill holding issue is all a clutch issue?!
I'll either buy some pushrods, or have the rocker stands all milled & put my NOS pushrods in...
Think I'll just have my local machine shop rebuild the starter for me...
Feel free to throw suggestions/cautions/questions out... I hope to start purchasing parts in a week or two, start tearing into it in a month or two...
Take care guys!
 






LUK is stock OE clutch. .
 






Yep- Guess the Question is- How well have the LUK clutches held up under increased power & loads that you guys have generated when modding your 4.0's...
 






Yep- Guess the Question is- How well have the LUK clutches held up under increased power & loads that you guys have generated when modding your 4.0's...
It held up to my setup for a long time and honestly i think it was a better clutch than the POS stage 3, 3 puck i had..

I currently have a different trans,flywheel and clutch setup but run a dual friction. .probably one of the best clutches around
 






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