'02 5.4 2v rebuild
 

Hello good people of FTE! I posted a while back about just doing rod bearings in my '02 Expy, well I have decided now to just tear the whole thing down and rebuild since the motor had 210xxx on it anyways.

I would appreciate any and all tips or tricks from any of you that have done this before.

So far I have the engine out and have started the tear down.... Intake is off as well as valve covers timing cover and oil pan. I plan to get the heads off today or tomorrow.

Parts ordered so far are as follows:
-Crank kit with all matching bearings
-Head set that comes with head gaskets, intake gasket set, timing cover gasket set, valve seals, valve cover gaskets, and exhaust manifold gaskets.
-Piston rings
-One new connecting rod(for the one that spun the bearing)
-New rod cap bolts, head bolts, main bearing cap bolts
-rear main seal
-oil pump
-timing set(including both chains, tensioners, guides, and bottom sprockets)

Am I missing anything major here? I will post pics of my progress as I go for anyone else who might need them in the future.

Instead of the plastic chain tensioners use cast iron ones from an '98 Town Car.

The machine shop must use a very fine RA finish on the cylinders and deck surfaces.

Use the Motorcraft "special service" head gaskets to fill slight imperfections so you do not have to replace the HG's again soon.

I got all felpro gaskets. How good are the guides with the sets from the stores like advance?

O'Reilly's has Cloyes but OE is recommended. On the HG's I would only use the ones I mentioned. Ford use to recommend replacement of the heads not surfacing because most machine shops cannot get the proper RA finish. This area sometimes leaks with factory new engines and must be meticulous. Many retailers have failed in remanufacturing the Modular engines, you are brave. I am glad you know most of the bolts are TTY and you have replacements. Since you are replacing a rod are you considering balancing the engine? Good fortune.

A couple of points. On the main caps, number them as they have to go back on where they came off. Connecting Rods are what they call crack style rods(the rods and caps are made as one piece then broken apart at the factory), if you mix up the caps and the rods you are screwed and will have to buy a whole new set.

I would recommend getting the book: How to build max-performance 4.6-liter ford engines by Sean Hyland(it covers both 4.6 and 5.4 engines)

Well I have the engine torn down ready for cleaning. Cylinder bores look good and piston looked good aside from a little carbon build up. Cams and bearings in good shape still and valves had just a thin layer of build up.

Really surprised how clean and all things were. Aside from whatever happened to the #8 rod bearing id say it could have went a lot longer before rebuild.