I have a 1997 F150 4X4, the engine is locked up tight due to it being run without oil, (go figure) and I need to do a replacement. It has a 4.6L V8 Coupled up to a 5 speed Manual Tranny. It has a 6 on the 8th digit of the VIN. My question is: What engines can I replace it with? Is it possible to rebuild one of these engines? The local Ford dealer is rather unhelpful due to a lack of knowledge of replacing the motor with anything but a NEW one which is financially beyond my means. (I'm a retired Marine E6)


I am a machinist and have a pretty good past experience working on machinery. I've never rebuilt a modern engine, last one was a V-8 60.


Thanks


Help is appreciated, GOOD help is golden.

 

A VIN 6 modular V8 engine is a Windsor engine, not to be confused with the older small block Windsors. The VIN W is a Romeo. You would think the W would be Windsor. I guess they just did that to mess with us.
The Windsor modular engines are built stronger than the Romeos although they both are rated the same on paper for the same application. There are small differences that you should research before you consider trying to mix and match any parts. It is best to go back with a Windsor engine such as you already have.

Regarding a replacement engine, likely the most cost effective thing would probably be to get a running engine out of a salvage yard. A reputable seller will usually give you some warranty on parts but not labor. Usually if it drove all the way to the wreck the engine is still good.

You should be good to swap in a long block for any 2 valve Windsor 4.6, but if you get a later one with PI heads you will need the engine computer from that truck or have yours retuned.
If your 5 speed is a M5OD, you will want to stick with the 4.6. The 5.4 V8 and 6.8 V10 will bolt up but will shred that light duty 5 speed soon.

I have a current project putting a V10 in an F150. I bought a wrecked van and have been parting it out so that the engine and transmission parts I want are at a ridiculously cheap cost to me, not counting my labor. If you have the space to work in and the time to wait for a deal like that, you could likely find something like that in your area. My F150 already had the same 4R100 transmission as the donor V10, so that made it much easier.
In this area, there are several very active Facebook groups to buy, sell, & trade cars and parts. There are some great deals to be found if you know what you are looking for. Or check Craigslist or call around to local salvage yards to see what is available and what it costs. You might find a truck with a great engine that needs a transmission

It is possible to rebuild a Ford modular V8, you would need to get it apart and see what the damage is to know what parts you will need to replace or it is possible that some or all of it is mangled and unusable. There may be a tipping point where the machine work and cost of replacement parts could exceed the cost of a known good engine.

 

A Winsdor 4.6 is much harder to find than the Romeo. since you have the 5 speed......pretty much only the winsdor will work. the winsdor has 8 bolts for the flywheel, and the Romeo has 6 bolts. I went through this with my 97 as well. someone tried to put a Romeo in it and the flywheel stopped that. and alot of parts was missing. so I had to find a complete winsdor to put in my truck.... so dont let anyone say a Romeo will bolt in....It wont. even the valve covers are different.

 

just went through this this fall. scrapers all wanted 900.00 for motor. went on craigs list searched a few locations. found one same price. showed him 700.00 cash and drove it home. Pulled two motors installed one. used a lot of other parts. fixed three trucks with it. got a 100.00 for scrap. Drives real good and have a spare set of tires.

 

I would pull the plugs, Marvel Mystery Oil in the cylinders and free it up first. These engines are pretty tough you may just get lucky as long as it didn't spin a main.

 

Find a used one that you can rebuild and start there. See my older posts where I rebuilt my 4.6 Windsor that had 386,000 miles on it and now I have 400,000 plus on the truck. Starts and runs PERFECT and I get better gas mileage now than when it was new. EASY rebuild.....just I.D. those spark plug wires EXACTLY where they go. Don't get them mixed like I did. Good luck