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I think that they would be near the same. I had a 99' 250 w/ the 5.4 it had 56,000 miles when I purchased it, and got rid of it at 85,000. I had not one problem with it, but the 4R100 was replaced before I got it. Currently I have an 04' CC SB w/ the V10 and it runs a smoothly as the 99', but with WAAAAYYYYY more power. Hoping to get well over 100,000 out of it.
Maybe the length of the V10 and the lack of length of the 5.4L brings out different problems mechanically....and knowing Ford, they have different sources for 6.8L parts and 5.4L parts.
The 5.4L has a MUCH larger installed base over the V10 but both motors have reliability (when properly broken in and serviced) figures well above average.
Most of the failures can be traced to abuse, misuse, or lack of preventative maintenance. There are always going to be defective parts, miss matched tolerances (under size piston in over size hole but with in specification) and the occasional poor assembly by distracted, disgruntled, or inept assembler.
But a properly assembled, broken in, normal use, and frequent air filter and oil / lube service makes the Ford Modular series v6 v8 and V10 some of the most reliable engines ever put in an American vehicle.
I would think just because the v10 has that many more moving parts it would be SLIGHTLY less reliable than the 5.4, but thats not to take anything away from the v10, they are both very reliable engines.
This may be wrong, but i remember reading somewhere that the v10 uses a two piece crank or something ot that effect, that could also impact reliablity. (i recall reading this causing problems in supercharged situations, but i could be wrong.)
Given the same exact gearing, loads, total weight, driving habits, etc, here's my opinion:
The V10 has an extra main bearing and two more rod bearings, pistons and cylinders.
Given exactly the same truck and work load, the 5.4 is going to be putting more load on each of those 5 main bearings than the V10 will. If it takes 100ft/lbs of torque to move a load, that 100ft/lbs is going to be distributed across a larger number of main bearings.
Likewise, each cylinder will be required to supply 1/8th of the total load in the V8, but only 1/10 the total with the V10.
Result? The load will be distributed over a greater number of internal working parts, lengthening the life of said part.
So, again, in the exact same situations, the V10 should last 25% longer. Or is that 20%? Or something like that.
The question is, can you possibly keep your foot out of it and NOT use the extra power of the V10?
As to more internal parts, caption p4, the 3-valve V10 does not have VVT while the 5.4 goes. Which probably means even MORE internal parts in the V8
Interesting way to look at it, never herad it that way before.
Diesel guys are always talking about the I6 because of less moving parts, I can throw this at them the next time it comes up, haha.
Do you know if what i said about the crank is true or if i'm remembering incorrectly?
Well, the comparison only works when you compare a 5.4L and a V10 because all the bearings are the same part #'s, rods, etc (pistons are diff compression, at least in the 3-valvers). The I6 is a much different design than a PSD V8, so no analogy there.
The crank is a "split pin". Instead of a continuous rod journal for both #1 and #5, the V10 has to incorporate an 18 degree difference between the two. This makes the crank a slight bit weaker, but they make up for that with a forged steel crankshaft. Not sure that the 5.4 V8's "steel" crank is forged or not.
The problem with a blower is when getting into some SERIOUS boost, the front of the crank flexes. Someone engineered a crank snout support, but have no idea who.
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