! Are you sure it's not just a Bad freeze plug or gasket?
Rusted engine block
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Super Moderator
Joined: Jan 2008
Posts: 40,035
Likes: 1,521
From: Maine, Virginia
Rusted engine block
As the title suggests, the engine block is rusted through.
My brother in law up in Maine has a 2000 F-350 V-10 and the engine block on the passenger side is rusted through and spraying coolant. It's not a freeze plug issue.
The truck only has 84K miles on it and as you can imagine, spends the majority of it's life sitting.
He's had to work through plenty of issues with the manifold studs and while doing all this, he noticed that the block seemed to be thin in places. Now it's let go completely.
Is this an issue that's been addressed before on here?
Is there a fix other than replacing the engine?
I suggested an engine swap but I guess if the core can't be rebuilt then he wouldn't be able to recoup the core charge.
Any and all thoughts and suggestions on this would be helpful so i can pass along to him.
My brother in law up in Maine has a 2000 F-350 V-10 and the engine block on the passenger side is rusted through and spraying coolant. It's not a freeze plug issue.
The truck only has 84K miles on it and as you can imagine, spends the majority of it's life sitting.
He's had to work through plenty of issues with the manifold studs and while doing all this, he noticed that the block seemed to be thin in places. Now it's let go completely.
Is this an issue that's been addressed before on here?
Is there a fix other than replacing the engine?
I suggested an engine swap but I guess if the core can't be rebuilt then he wouldn't be able to recoup the core charge.
Any and all thoughts and suggestions on this would be helpful so i can pass along to him.
Hotshot
Joined: Mar 2007
Posts: 10,101
Likes: 40
From: Pa
Not something that is too common. My guess is a thin spot, porosity or something along those lines coupled with rusting (made worse by lack of use) caused it to spring a leak. Though it is possible his coolant could have a charge and eating the block from the inside out.
It depends where the leak bad spot is in the block and how the thin the surrounding area is whether it is viable for repair. The best way to repair a cast iron block so it lasts is with metal stitching. It is something that is kinda a lost art these days but there are still some around that can do it, and it can be learned.
Metal Stitching & Thread Repair Inserts. - Turlock , CA - LOCK-N-STITCH, Inc
It depends where the leak bad spot is in the block and how the thin the surrounding area is whether it is viable for repair. The best way to repair a cast iron block so it lasts is with metal stitching. It is something that is kinda a lost art these days but there are still some around that can do it, and it can be learned.
Metal Stitching & Thread Repair Inserts. - Turlock , CA - LOCK-N-STITCH, Inc
Thread Starter
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Super Moderator
Joined: Jan 2008
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From: Maine, Virginia
I told him then to do an engine swap or else he'll be in a bind and won't get any more back on the engine than what some parts are worth and scrap price for the iron block.
IMHO he's screwed but I wanted to tap into FTE's immense knowledge and hopefully get proven wrong.
Tuned
Joined: Mar 2015
Posts: 293
Likes: 45
From: In the 860
No immediate advice unfortunately.
But a few years back, my brother had a '98 F-250 L/D plow truck with a 5.4. It was a local truck (CT) is whole life, and very rusty. I could not believe the scale on the engine block (the exhaust manifolds had rotted right off the truck). Having seen that, I can totally believe rust through of an engine block in a similar (albeit worse) environment, similar engine, etc.
But a few years back, my brother had a '98 F-250 L/D plow truck with a 5.4. It was a local truck (CT) is whole life, and very rusty. I could not believe the scale on the engine block (the exhaust manifolds had rotted right off the truck). Having seen that, I can totally believe rust through of an engine block in a similar (albeit worse) environment, similar engine, etc.
Mountain Pass
Joined: Sep 2002
Posts: 155
Likes: 6
From: Suburban Washington DC
If the salt up there is bad enough to eat through the block, he better take a real close look at the frame before throwing good money after bad on a 16 year old truck. I crawled underneath my 2006 Town Car and saw the block and manifolds with chunks of rust everywhere but it had over 300,000 miles and was a mid atlantic car so who knows.
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Cargo Master
Joined: Jun 2010
Posts: 2,113
Likes: 4
From: Iowa
The truck is in Maine and I'm in Va. My BIL was telling me about this a couple years ago. He stated then that he felt the side of the block was weak and the rust was flaking off in thick layers. It's not a freeze plug. My BIL is as good of a non Ford tech mechanic as I've ever seen.
I told him then to do an engine swap or else he'll be in a bind and won't get any more back on the engine than what some parts are worth and scrap price for the iron block.
IMHO he's screwed but I wanted to tap into FTE's immense knowledge and hopefully get proven wrong.
I told him then to do an engine swap or else he'll be in a bind and won't get any more back on the engine than what some parts are worth and scrap price for the iron block.
IMHO he's screwed but I wanted to tap into FTE's immense knowledge and hopefully get proven wrong.
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Cargo Master
Joined: Apr 2013
Posts: 3,087
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From: Central Florida
I grew up in Michigan where rust is a bumper crop. I've seen rusty blocks, exhaust manifolds and body/frames. Never such a thing as cast iron engine block rusting through.
And if I'm somehow wrong; there's no way the rest of the truck is worth keeping.
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Super Moderator
Joined: Jan 2008
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From: Maine, Virginia
Me too. I don't believe this until I see it.
I grew up in Michigan where rust is a bumper crop. I've seen rusty blocks, exhaust manifolds and body/frames. Never such a thing as cast iron engine block rusting through.
And if I'm somehow wrong; there's no way the rest of the truck is worth keeping.
I grew up in Michigan where rust is a bumper crop. I've seen rusty blocks, exhaust manifolds and body/frames. Never such a thing as cast iron engine block rusting through.
And if I'm somehow wrong; there's no way the rest of the truck is worth keeping.
He just replaced the rockers and cab corners this summer and did some work to the rear quarters. While the body was off he did the frame as well and sprayed it black. Looked like a nice thorough job.
But, he still neglected to address the engine issue. I'm thinking that he was surprised of the block rust as we all are and just didn't believe that it could be that thin.
Thanks for all of your comments thus far.
Cargo Master
Joined: Jun 2010
Posts: 2,113
Likes: 4
From: Iowa
It sounds like he has a very nice looking truck for its age but it also sounds like he is mostly knowledgeable in bodywork? There are three types of guys, truck body restores, mechanical gurus and the rare Master of both, all are great at what they know.
Elder User
Joined: Jul 2005
Posts: 974
Likes: 11
Years ago, I owned a 1999 Dodge with 5.9L Cummins. One of the engine casts was known to have a weak/thin spot which could lead to engine block cracks on highly mod'd engines (you can Google "Cummins Cast 53" to get a ton of reading info). Quite a few guys were able to successfully seal cracks using JB Weld on a carefully and properly prepared block (lots of cleaning, etc.). Anyway, just wanted to throw that out as a possible solution to your described problem.
Good luck.
Good luck.
Thread Starter
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Super Moderator
Joined: Jan 2008
Posts: 40,035
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From: Maine, Virginia
To close the loop on this one, my BIL went to a salvage yard in Brewer, Maine and bought a V-10 that came from a wrecked SD and installed it in his truck. The donor had 140K miles. He pulled the valve covers and oil pan prior to the install and said it looked great. The engine cost about $1700.00 delivered to his house. It also came with a 90 day warranty.
Thank you all for your offerings. I have to agree, it was likely a casting issue. He at least has some great spare parts from his old engine and heads, maybe he can part them out.
Thank you all for your offerings. I have to agree, it was likely a casting issue. He at least has some great spare parts from his old engine and heads, maybe he can part them out.
Mountain Pass
Joined: Sep 2002
Posts: 155
Likes: 6
From: Suburban Washington DC
Good he got it figured out but he could have bought a complete driveable salvage truck for half that. If time and convenience were more important then I can understand.
