This is a build thread for starters. On my 99 Explorer 4.0 4WD. I posted a thread recently getting confused. But I am positive on the problem now....so its time to rebuild this motor. I won't give up on this beast.

So what I realized after a while was that I was hearing timing chain rattle in the front of the motor. When I stuck my stethoscope in I could never pinpoint the noise location, so I wrote it off as exhaust rattle. So now that its cranking, but the cams are not moving...it must be timing chain problems. Here is where I learned this stupid thing about these 4wd 4.0 SOHC's....they have not 1...not 3....BUT 4 Timing chains. Then I found out a little more of a scary thing...HAVE to pull the motor to access the back chain. I won't take the chance and not replace them all. While I am that deep in I am going to go all the way. Full rebuild. Here is what I have listed as parts I am getting for the rebuild. Note: This does not include fluids and stuff like that. Just engine internals.

Cloyes 903998SB - Full timing set down to the sprockets - 293.74
DNJ PR422 - Piston Ring Set - 33.89
FelPro TCS45986 - Timing Cover Gasket - 16.56
Gates 43279 - Waterpump/Gasket - 40.79
DNJ FGS4028 - Engine Gasket Set - 146.79
Anchor 2850/2851 - Both Motor Mounts - 15.39
EngineTech HB173 - Headbolts - 32.96
Continental 4060865 - Belt - 12.11
Timken 2012V/3393 - Front and Rear Main Seals - 22.33

This is what I have come up with so far. I plan on checking all the bearings out before I order some to see if I need them or not. If mine are in good shape, I will leave them. As well as the valves. I plan on rebuilding the steering pump(leaks), Alternator, and A/C(leaks) myself out of my own supplies. Really not that hard to do. This motor is going to be taken all the way down and I will machine the entire thing as I go. As well as give it a paintjob all the way up.

This is no build for the faint of heart. To start it all off...the differential is very much so in the way for accessing the starter and then the TC bolts afterwards. So its best to remove it completely and move it out of the way. JACKSTANDS are a must. Since I removing the differential...I will be freshening it up as well as replacing all of the front suspension. Its pretty crappy. All of it is. Bad shocks, bad upper joints, coils are getting old. So I will replace it with new and add hopefully a 3 inch lift while I am there.

Once I recoop my big tools(were stolen), I will be starting on this and I will do plenty of photos so maybe people can use some of these tips and tricks I hit along the way. Will keep everyone updated!!

 

Sounds like fun. I have been into many of these engines so just ask if you run into any problems. Make sure you get the cam timing tools they are required to set up the chains. Also the rod, main cap, crank pulley, both jackshaft chain, and head bolts are torque to yield and should not be reused. I would recommend going with the OE Ford timing parts they are much better quality than the aftermarket stuff.

 

I would love to go with Ford's stuff. But the price is a no go for me. Cloyes is pretty good on their timing products. The Ford pricing is nearly 4 times the cost of ALL of my parts just for their timing stuff. And it was their timing stuff that ended this motors life at just over 100k. Lol. I already know the head bolts are TTY, but I did not know about the other ones. So I will be hitting up fastenal for those I am sure. I most certainly will be asking questions. I always run into issues. Lol.