Has anyone here rebuilt the 4.6 dohc windsor?
Anything to look out for specifically?

 

There are no DOHC Windsor engines.
Are you referring to the 4.6L that's in the truck in your signature?
If so,that's a SOHC engine.
JL

 

My 1997 ford OEM service manual says different:

#1) My "eight" vin number is "6"......Page 100-01-0 of MY manual says it's a
4.6l (280 cu in), DOHC v8, gas, efi, WINDSOR.

#2) Drivers side, located on the valve cover is: ford windsor, ontario canada.

#3) Page 303-01b-2 of MY manual (lower rh corner) figure 4...(wep).
I have diagram 4 on my truck.

Again, per MY manual.

I have not started any work yet so I'll see more I'm sure.

 

YOU DO NOT have a DOHC 4.6L in you truck. That maual is WRONG.
JL

 

JL

You are CORRECT, the manual is WRONG and I have red lined the error to show SOHC not DOHC.
With that in mind I never thought that I had two cams per head. I thought you was talking about rep vs a wep and I was certain I have a windsor.
Anyway, thanks for the headsup. The manaul I have is actually full of errors especially numerical torque values.
Can you change the topic to show SOHC?
Actually, I'm leaning away from the thought of rebuilding this engine since it seems beyond the average persons reach. This engine requires "TIGHT" accurate machining processes and a lot of builders will not touch it. Ford wants around $3500 for a rebuild engine with exchange so, I may go this way.
My concerns are the engine has over 340k miles on it and I saw some coolant on the block the other day that bothers me since I don't know where it came from. I cleaned it up and it has not reappeared but it could be a head gasket getting ready to fail.
The engine still starts and runs like new (because of my maintanance) but I think it's just about at the end of the road.

 

Where was the coolant? I've seen many intake gaskets fail with really high mileage, and they will leak around the coolant crossover ports on the intake and puddle in the valley of the block,etc.
JL

 

The coolant was found in the #4 spark plug cavity (about 2 table spoons) and on the drivers side just under the fwd spark plug but not in the cavity.
I cleaned it up and have not seen it since.
The fact that it was found on both sides, pass and drivers side makes me wonder if it really is both head gaskets failing at the same time or if it's leaking from some hose or something. If it is a hose I will just keep running the engine for a while longer but if it is the head gasket I will pull it out NOW, because I don't want to blow the engine.
There seems to be several salvaged engines for sale that have less than 100k miles for under $1k, which seems like a reasonable deal for me.

 

There are coolant passages on the front and rear of the cylinder heads at the corners,and it's common to see leaky gaskets that will fill the spark plug wells with coolant.
I'd start with a set of intake manifold gaskets.
JL

 

What's an inexpensive good gasket for the intake manifold?
From ford or?

 

There aren't many choices. The OEM gaskets are a plastic main body with captive rubber o-ring seals.
JL

 

So are the Fel-Pro gaskets from Advanceauto/ AutoZone or Rock Auto.
Rock Auto has the best prices.

 

Any of them-doesn't really matter.
JL