5.4 Rebuild
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Senior User
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5.4 Rebuild
I have not much experience in this area .... I am getting a F250 that has a "bad engine" as far as I know it runs but uses oil so bad you cant drive it. There is also a huge oil leak under it and I cant see where it is coming from.
I was told it needed a rebuild and thats what I intend to do since its highler mileage anyways.
I need to be pointed in the right direction. I plan to do it all myself with a friend or two. No shops. I will buy any tools I might need for this... But what do I buy for the engine?
Overhaul kit? There are different kinds im not sure what to do? Should I just tear it down and re do what I can like bearings, rings, gaskets ...?
Can anyone I guess link me to a solid source for something to buy. I really need to stay under 1000 dollars but I would really REALLY like to be under 500 if thats even possible.
I was told it needed a rebuild and thats what I intend to do since its highler mileage anyways.
I need to be pointed in the right direction. I plan to do it all myself with a friend or two. No shops. I will buy any tools I might need for this... But what do I buy for the engine?
Overhaul kit? There are different kinds im not sure what to do? Should I just tear it down and re do what I can like bearings, rings, gaskets ...?
Can anyone I guess link me to a solid source for something to buy. I really need to stay under 1000 dollars but I would really REALLY like to be under 500 if thats even possible.
Fleet Mechanic
Joined: Aug 2008
Posts: 1,446
Likes: 9
From: NE Iowa JD Country
I have not much experience in this area .... I am getting a F250 that has a "bad engine" as far as I know it runs but uses oil so bad you cant drive it. There is also a huge oil leak under it and I cant see where it is coming from.
I was told it needed a rebuild and thats what I intend to do since its highler mileage anyways.
I need to be pointed in the right direction. I plan to do it all myself with a friend or two. No shops. I will buy any tools I might need for this... But what do I buy for the engine?
Overhaul kit? There are different kinds im not sure what to do? Should I just tear it down and re do what I can like bearings, rings, gaskets ...?
Can anyone I guess link me to a solid source for something to buy. I really need to stay under 1000 dollars but I would really REALLY like to be under 500 if thats even possible.
I was told it needed a rebuild and thats what I intend to do since its highler mileage anyways.
I need to be pointed in the right direction. I plan to do it all myself with a friend or two. No shops. I will buy any tools I might need for this... But what do I buy for the engine?
Overhaul kit? There are different kinds im not sure what to do? Should I just tear it down and re do what I can like bearings, rings, gaskets ...?
Can anyone I guess link me to a solid source for something to buy. I really need to stay under 1000 dollars but I would really REALLY like to be under 500 if thats even possible.
Sure you can prolly find over haul kits...but its going to be the machine work to prep the block and heads...etc, on top of that will blow your budget. Then factor in get tools and refreshments for your help....well I suspect you'll spend closer to $2500...depending on if you are well outfitted already with tools.
your more economical way it to get a running engine out of the Salvage yard and swap it out.
you can look at Summit or Jegs for OH kits for on line...but a good chatt at your local automotive machine shop will shed better lite
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Not sure if your going to be able to stay under those dollar amounts....on a overhaul.
Sure you can prolly find over haul kits...but its going to be the machine work to prep the block and heads...etc, on top of that will blow your budget. Then factor in get tools and refreshments for your help....well I suspect you'll spend closer to $2500...depending on if you are well outfitted already with tools.
your more economical way it to get a running engine out of the Salvage yard and swap it out.
you can look at Summit or Jegs for OH kits for on line...but a good chatt at your local automotive machine shop will shed better lite
Sure you can prolly find over haul kits...but its going to be the machine work to prep the block and heads...etc, on top of that will blow your budget. Then factor in get tools and refreshments for your help....well I suspect you'll spend closer to $2500...depending on if you are well outfitted already with tools.
your more economical way it to get a running engine out of the Salvage yard and swap it out.
you can look at Summit or Jegs for OH kits for on line...but a good chatt at your local automotive machine shop will shed better lite
Why cant I just go in and replace wear items and gaskets i.e. rings, bearings, valves and springs even??
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Senior User
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Like... would this work?
Ford 5.4L 1997-2005 Engine Rebuild Kit
or would I really have to spend the extra and get this
http://www.rpmmachine.com/shop/index...t_detail&p=718
Ford 5.4L 1997-2005 Engine Rebuild Kit
or would I really have to spend the extra and get this
http://www.rpmmachine.com/shop/index...t_detail&p=718
Fleet Mechanic
Joined: Aug 2008
Posts: 1,446
Likes: 9
From: NE Iowa JD Country
Like... would this work?
Ford 5.4L 1997-2005 Engine Rebuild Kit
or would I really have to spend the extra and get this
Ford 5.4L 1997-2005 Engine Rebuild Kit
Ford 5.4L 1997-2005 Engine Rebuild Kit
or would I really have to spend the extra and get this
Ford 5.4L 1997-2005 Engine Rebuild Kit
as far as why machine work is needed.... well that all depends really what kind of condition your engine is in?
A machine shop can ascertain the condition of your engine with special instruments and measuring devices...measure the journals on the crankshaft...taper on the cylinder bores, to see what is with in specification , as well as, check for internal cracks...to correct this wear...they have the specialized equipment to correct for this too. this takes time and is where $$ add up.
you can do some of this yourself if you know what to look for and have reasonable knowledge of tolerances and specifications and time to walk through it checking and rechecking often. and of course the tools
hope that helps
Cargo Master
Joined: Feb 2011
Posts: 3,450
Likes: 13
From: Forest lake minnesota
I guess the first thing I would do is verify that it needs any work to begin with , if it is leaking a large amount of oil find out where it is coming from, could be the oil cooler, could be a cracked filter housing , lots of possible scenarios, after that recheck for oil usage maybe after you fix all the leaks the oil usage might be within reason. Just my thoughts 
Junior User
Joined: Aug 2011
Posts: 53
Likes: 0
From: Jefferson, GA
Rebuilding an engine requires machine shop work. Oil leaks are not the reason why engines need to be rebuilt. There is something else wrong with the engine they are not telling you. I agree with the others, get the best looking salvage yard engine you can find for a low price. Call around to a bunch of places. Search on car-part.com.
Not an insult, but just judging from your post, it sounds like you may be in over your head. You have a lot more reading up to do. You are going to have to increase the allotted funds or pick a different project. I've spent around $2000 on the 4.6L build I am working on now for an engine hoist, engine stand, cam timing tool, engine with 51k miles, head gaskets, head bolts, bottom end gasket kit, cleaning solvents, replacement fluids, and about a dozen other things I'm sure that I'm forgetting.
My garage was already pretty well stocked with all air tools, ratchets, sockets, wrenches and other special tools needed.
Not an insult, but just judging from your post, it sounds like you may be in over your head. You have a lot more reading up to do. You are going to have to increase the allotted funds or pick a different project. I've spent around $2000 on the 4.6L build I am working on now for an engine hoist, engine stand, cam timing tool, engine with 51k miles, head gaskets, head bolts, bottom end gasket kit, cleaning solvents, replacement fluids, and about a dozen other things I'm sure that I'm forgetting.
My garage was already pretty well stocked with all air tools, ratchets, sockets, wrenches and other special tools needed.
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Senior User
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Rebuilding an engine requires machine shop work. Oil leaks are not the reason why engines need to be rebuilt. There is something else wrong with the engine they are not telling you. I agree with the others, get the best looking salvage yard engine you can find for a low price. Call around to a bunch of places. Search on car-part.com.
Not an insult, but just judging from your post, it sounds like you may be in over your head. You have a lot more reading up to do. You are going to have to increase the allotted funds or pick a different project. I've spent around $2000 on the 4.6L build I am working on now for an engine hoist, engine stand, cam timing tool, engine with 51k miles, head gaskets, head bolts, bottom end gasket kit, cleaning solvents, replacement fluids, and about a dozen other things I'm sure that I'm forgetting.
My garage was already pretty well stocked with all air tools, ratchets, sockets, wrenches and other special tools needed.
Not an insult, but just judging from your post, it sounds like you may be in over your head. You have a lot more reading up to do. You are going to have to increase the allotted funds or pick a different project. I've spent around $2000 on the 4.6L build I am working on now for an engine hoist, engine stand, cam timing tool, engine with 51k miles, head gaskets, head bolts, bottom end gasket kit, cleaning solvents, replacement fluids, and about a dozen other things I'm sure that I'm forgetting.
My garage was already pretty well stocked with all air tools, ratchets, sockets, wrenches and other special tools needed.
And yes im totally in over my head on this stuff. Never really done anything internally other than some crank bearings on my old SBC. But thats why I am here asking.
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From: Reynoldsburg, Ohio
As the others have already said no offense but rebuilding an engine with little or no experience can be much much more costly than the salvage yard/used motor route.
I'm not sure how valuable this new-to-you truck will be if its running well so I'd suggest looking at a Ford long block which is a somewhat easier exchange than the engine rebuild. Those typically run about $2700, $500 core charge with a 3 year/50K mile warranty too.
If its just a beater truck of sorts you're getting for a great price maybe Craig's List is a good source in your area? I found a '99 5.4 gasser motor with 85K miles for $1,000. Sadly it wasn't suited for my later model E250 so it had to be resold quickly.
There is some great advice to be had here, many having already done most anything being considered by others---well worth heeding their advice.
Best of luck--------hope this is a great truck once its finished!
I'm not sure how valuable this new-to-you truck will be if its running well so I'd suggest looking at a Ford long block which is a somewhat easier exchange than the engine rebuild. Those typically run about $2700, $500 core charge with a 3 year/50K mile warranty too.
If its just a beater truck of sorts you're getting for a great price maybe Craig's List is a good source in your area? I found a '99 5.4 gasser motor with 85K miles for $1,000. Sadly it wasn't suited for my later model E250 so it had to be resold quickly.
There is some great advice to be had here, many having already done most anything being considered by others---well worth heeding their advice.
Best of luck--------hope this is a great truck once its finished!
Thread Starter
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Senior User
Joined: May 2010
Posts: 294
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As the others have already said no offense but rebuilding an engine with little or no experience can be much much more costly than the salvage yard/used motor route.
I'm not sure how valuable this new-to-you truck will be if its running well so I'd suggest looking at a Ford long block which is a somewhat easier exchange than the engine rebuild. Those typically run about $2700, $500 core charge with a 3 year/50K mile warranty too.
If its just a beater truck of sorts you're getting for a great price maybe Craig's List is a good source in your area? I found a '99 5.4 gasser motor with 85K miles for $1,000. Sadly it wasn't suited for my later model E250 so it had to be resold quickly.
There is some great advice to be had here, many having already done most anything being considered by others---well worth heeding their advice.
Best of luck--------hope this is a great truck once its finished!
I'm not sure how valuable this new-to-you truck will be if its running well so I'd suggest looking at a Ford long block which is a somewhat easier exchange than the engine rebuild. Those typically run about $2700, $500 core charge with a 3 year/50K mile warranty too.
If its just a beater truck of sorts you're getting for a great price maybe Craig's List is a good source in your area? I found a '99 5.4 gasser motor with 85K miles for $1,000. Sadly it wasn't suited for my later model E250 so it had to be resold quickly.
There is some great advice to be had here, many having already done most anything being considered by others---well worth heeding their advice.
Best of luck--------hope this is a great truck once its finished!
It wont be a beater truck but it will never be a daily driver and I will never need to rely on it... Its going to be a mud truck. Its a 2wd and I have a divorced Tcase for it chevy 3/4 axles, plans for big lift and 40" tires.
I will start a build thread for it tomorrow when I get the truck....
What about putting a 460 BB in it? I am going to search for adapters and such to even see if thats an option.
Elder User
Joined: Nov 2007
Posts: 528
Likes: 1
From: Canada, ON New Market
I appreciate it but 2700 is just not there and wont be for a project.
It wont be a beater truck but it will never be a daily driver and I will never need to rely on it... Its going to be a mud truck. Its a 2wd and I have a divorced Tcase for it chevy 3/4 axles, plans for big lift and 40" tires.
I will start a build thread for it tomorrow when I get the truck....
What about putting a 460 BB in it? I am going to search for adapters and such to even see if thats an option.
It wont be a beater truck but it will never be a daily driver and I will never need to rely on it... Its going to be a mud truck. Its a 2wd and I have a divorced Tcase for it chevy 3/4 axles, plans for big lift and 40" tires.
I will start a build thread for it tomorrow when I get the truck....
What about putting a 460 BB in it? I am going to search for adapters and such to even see if thats an option.
Thread Starter
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Senior User
Joined: May 2010
Posts: 294
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Appreciate the response and have been though lots of ideas for my project. Did go out and buy a 460 and c6 combo but I have decided to resell it and probably rebuild this engine as I can since the truck is going to be a project for a while!
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Senior User
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Me too!
This is the best I can do for a sound clip
There are more grinding and metal clanking noises than you can hear in the video.
Hardly stays running. Wont rev pas 2k.
Apparently bad rings
Very smokey
This is about 2 minutes of running just on the trailer to get it off
It stalls/misses/shudders/grinds......
OH!
And it doesnt even have a check engine light.
This is the best I can do for a sound clip
There are more grinding and metal clanking noises than you can hear in the video.
Hardly stays running. Wont rev pas 2k.
Apparently bad rings
Very smokey
This is about 2 minutes of running just on the trailer to get it off
It stalls/misses/shudders/grinds......
OH!
And it doesnt even have a check engine light.
Freshman User
Joined: Sep 2010
Posts: 31
Likes: 0
From what I have read here you have a project truck that you are going to put in mud with oversize tires and nothing under the hood to make the tires turn. If it rattles and smokes and won't rev past 2 grand then I'd bet it is worn out which means it needs boring, pistons, rings and bearings, rods reconditioned, etc. Valve guides could also be worn out so there is more machine work and money, crank probably needs turning from the egg shaped rods that are hammering on it while it is trying to run. So the way I see it is that if you don't want to spend more than $500 dollars then your best bet is to part the truck out and forget about slinging mud. Its real simple, a powerplant that knocks, smokes and barely runs won't pull gumbo mudders. Take the money you would spend on the tires and wheels and put it under the hood first. Then buy the tires and wheels for slinging mud. Sorry, but rings and gaskets won't fix an engine that is worn as bad as yours seem to be. Hope this helps.