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Why would he think he has a cracked cylinder wall? What are the symptoms that would cause him to think this w/o having taken the motor out?? If the block has a visible crack that is leaking thats a different story...Rebuilds ALL depend on who does the work....You might want to check ebay..I see BRAND NEW 5.4L engines all the time and they go for around $1200-$1500.00...Definitely a better option than rebuilding. UNLESS you want to toughen up the internals.......
Don't think anyone sleeves the 5.4 Iron blocks...only 5.4's I'm aware of that get sleeves are SHM aluminum modular blocks....and I don't think he'll be getting one of those... Anyway, if he's looking at a rebuild he may as well get a good forged shortblock for VT Engines or SHM or anyother company that specializes in building modular Fords. I think the VT shortblock runs about $3,800 not including freight. The 5.4 blocks are damned stout...takes something seriously wrong to crack one..maybe he's just loosing a rod...those and the pistons are the weak points in these motors.
I haven't heard of any block problems either. I figured that you could sleeve any engine.
Unless it froze up and busted or something got in the cylinder, I don't know why it would crack.
Don't think anyone sleeves the 5.4 Iron blocks...only 5.4's I'm aware of that get sleeves are SHM aluminum modular blocks....and I don't think he'll be getting one of those... Anyway, if he's looking at a rebuild he may as well get a good forged shortblock for VT Engines or SHM or anyother company that specializes in building modular Fords. I think the VT shortblock runs about $3,800 not including freight. The 5.4 blocks are damned stout...takes something seriously wrong to crack one..maybe he's just loosing a rod...those and the pistons are the weak points in these motors.
Iron blocks can be sleeved. We do it all the time, but something seems not right about the beginning of this thread. The modular block is very stout and cracks in the cylinder walls are pretty rare. If there is a crack it is more likely to be in the webbing or in a water passage from overheating.
But, if it is in the cylinder wall, it can be sleeved if the crack does not extend too far down into the block or into the webbing.
BTW, I raced a showroom stock smallblock MOPAR back in the '70's. When we rebuilt that engine, in order to keep it legal in class, we put eight sleeves in it and bored it back to standard size! No problem. Would be cost prohibitive if it was not a race engine.
... The 5.4 blocks are damned stout...takes something seriously wrong to crack one..maybe he's just loosing a rod...those and the pistons are the weak points in these motors.
I'm not sure how "damned stout" they are - looking through the right inner fender of my 98 Expy, I see a hole in the side of my 5.4 big enough to stick my fist through...doesn't seem too "damned stout" to me!
I have no idea what went wrong - don't know if it sucked a valve then detonated the piston and connecting rod or what...I've got pieces of the piston and the rod (the half that connects to the piston). The rod is twisted at the broken end.
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