While you're at it's

[JakePSD]

Got a few questions for you guys regarding a couple 02 sohc 4.0l engines. The explorer has I'm assuming blown head gaskets. It won't run, and even cranking the engine results in coolant being blown out of the reservoir cap. I've already pulled that motor out. I'm getting ready to pull the running motor out of a mountaineer to drop into the ex. I'm considering fixing the ex engine for a spare or to possibly drop back into the mounty if I decide to fix it up.

Since the engines are already out and since the timing components are known to be problematic on these, how long does it usually take to replace the entire system? And what does it usually cost? I'll be doing the work myself, and I'm pretty competent when it comes to working on vehicles. I've seen threads about this in my searching but most are pretty old threads. Not sure how up to date the info is. Also what other things would you guys recommend me do while the engine is in an easy location to work on? Where can I get the timing tools affordably?

 

[imp]

....... Where can I get the timing tools affordably?

I've seen a few threads where the timing was set without the special tools. I've never done it, but can picture what the problems are: mainly, the valve springs which happen to be under tension wherever the crank may have stopped, will try to rotate the camshaft when the chain is loosened/removed.

So, the first thing is to make a device which will "lock" the camshaft from turning.

The other, is the scheme by which two grooves in the front face of the sprocket, are to be aligned with the head surface, this done with No. 1 cyl. at TDC.

I'll try to find the pics I have buried somewhere, just in case you choose to not spend money on special tools. imp

 

[JakePSD]

I'd love to not have to spend $$$ on a tool I'm only gonna use a hangul of times. Really I could probably make it or talk to the tool and die guys at work and they could if I knew detailed dimensions. Those guys tend to have a lot of free time and will make all sorts of crap for you for a coffee.

 

[JakePSD]

Realized something interesting, the engine I pulled out of the 2wd ex has a balance shaft. Must not be the original engine. I'm thinking about doing the water pump while I have the engine out, as well as spark plugs. Those will never be easier to change. Anything else you guys would suggest? Also, what the hell is that bolt in the power steering res bracket for? I've seen numerous trucks with the 4.0 and they all have that bolt that's just, there. It holds nothing. And what is the spongey thing in the valley? Is it just that, a sponge to soak up any oil that leaks there? The mounty engine has one, but the ex didn't.

 

[JakePSD]

Since the engine is out and I'm considering doing the timing stuff when its the easiest, do I need to replace the chains too or can I safely get by with just doing the tensioners and guides? If I do just those do I need the special tools? Should I stick with only motocraft parts or are some other options just as good?

 

[JakePSD]

Also, what do you guys think about just rebuilding the whole engine? I'll have it torn down to almost nothing anyway pulling the heads. Can I throw new bearings and rings in without any machine work?

 

[mmasire88]

I would absolutely suggest replacing timing components while your motor is out. The OTC 6488 timing tool kit will make your life much easier as well. I recently finished replacing the motor in my ex with a 2005 mustang long block, upon removing the valve covers on the mustang motor, the right timing chain cassette was indeed broken in several places as was the main chain assembly tensioner and the motor only had 97k. The process really isn't all that bad once you install the tools to hold the cams and crank in place while you remove/replace the timing components. I purchased the OTC 6488 kit for 180$ on amazing, and than once I was through with it I actually sold it for 195$ locally. I would also recommend using OEM ford timing chain related components as they seem to be the best quality. I initially purchased an Autoparts4usa kit, but the quality of the components were below my liking.

These seem to be the most problematic of the timing chain related components on these motors. The right cassette, and main chain tensioner were broken on both the new motor and the motor I took out of my truck. The left cassette assembly was pretty worn @ 172k on my original motor, but it was fully intact with no breaks.

 

[JakePSD]

How much did it cost you at the dealer to buy all that stuff? Do I need chains or can the old ones be reused safely? What do you think about what I said about going through the whole engine?

 

[JakePSD]

Called the dealer this morning, gonna be about $600 after tax. Sound about right? Any thoughts on reusing the chains and going through the whole motor?

 

[mmasire88]

I purchased most of my oem parts from eBay. What all is included in the 600$ price? I can't imagine that would be everything, seems a little on the cheaper side. I paid about 120$ for each cassette assembly, which included sprockets, chains, cassette. Than I had to purchase the torque to yield bolts separately(very important, do not forget these). For the main chain assembly I just replaced the tensioner, as the guide and chain were in excellent shape. Chains I believe are capable of lasting several hundred thousand miles so in my opinion they are not necessary to replace(depending on your mileage). However, I was unable to find just the cassette without the chain and sprockets, and you have to take the whole assembly (chains/sprockets) out as one part anyway, so you might as well replace it all.

 

[JakePSD]

Supposedly it included all 4 chains, tensioners and guides. I didn't know exactly what I needed so I had them figure it out, which is probably inaccurate. Parts desk guys don't always know their ass from a hole in the ground. If I had an exact list I could get a more accurate price but honestly I don't know exactly what I need. Can anyone give me a list? If I can save some cash on the chains and not replace them that'd be cool.

By the way. I just bought the OTC 6489 Ford Master Timing Set on eBay for $175 shipped. It includes everything in the 6488 set, plus a bunch of other stuff. This set usually sells for around $350. Its missing 2 pieces which are for older model 4.6, and I found those for $50. Score in my book.

 

[JakePSD]

Oh, and I'd like to delete the balance shaft while I'm in there. Less parts to fail, and less rotating mass, which equals more horsepower, less fuel consumption, and better throttle response. The difference may be negligible and unnoticeable but it also saves me some coin on the timing chain service. Less parts to buy. The only thing I have to do is remove it and plug the oil holes right? And if I remember correct from my reading can't I just use a standard pipe thread plug for them?

 

[SideTrackTap]

Part Numbers

2000StreetRod has a list of all the timing component part numbers here: http://www.explorerforum.com/forums/showthread.php?t=316665

I just recently bought my left cam timing cassette, balance shaft tensioner, and the main/jackshaft timing kit from: http://parts.autonationfordwhitebearlake.com/ So far they have had everything in stock and their prices are some of the best as far as I can tell. They usually ship the same day.

Chris

 

[JakePSD]

I will check them out.

Does anyone have any objections to my idea of removing the balance shaft?

 

[JakePSD]

No input on the balance shaft delete?

 

[JakePSD]

I'm getting ready to go through the mounty motor this week. Any thoughts on deleting the balance shaft? Also looking for more input on just replacing the tensioners and guides. We are trying to get through this as cheap as possible. If I get this whole project done cheap enough, after parting out one of the 3 trucks I have, I might end up with 2 free trucks. So far I'm only $1800 deep in the whole thing.

 

[JakePSD]

Maybe taking this to the top in the evening will get some responses?

 

[JakePSD]

Anyone?