2004 XLT at the Crossroads

Larry Holmes · Nov 22, 2024

I had a local shop drop upper and lower oil pan assys to stop the leak and they found the plastic timing chain guide pieces and a couple of half-moon pieces of metal. So I am having them button it back up and maybe drive it until it drops. It honestly didn't exhibit any issues prior to this but the guides do have lifespan issues. I could get a Ford or Jasper reman an pay the 10 grand parts and labor (comes with parts and labor warranty). I could also get a long block cheaper, around 3 grand and have a different shop install it: I have had luck in the past with bringyourownparts.com. Besides picking a used engine from a jy, what have other Gen 1 ST enthusiasts done? It reminds me of having to put an old dog down.

Todd Z · Dec 4, 2024

They don't last forever anymore and are not cheap, the other issue is buying quality timing parts, Ford has discontinued most of it. So you go through the hassle of rebuilding for it only to fail again.

Larry Holmes · Dec 5, 2024

After exploring options I ordered a used VIN-matched engine with ~86K miles. If I get another 86K with it I'd be satisfied. First thing when it arrives is drop the lower pan to see if there's any like debris while holding my breath in suspense. Also found a mechanic to do the swap on-site. The bottom line is about almost $4K. A new remanufactured long block with installation is >$9K.

SwampTrac · Dec 5, 2024

This is good to hear. Fingers crossed theres no plastic in the pan! 4K isnt bad when you think about it, imagine finding a truck with 86K for only 4K. Thats impossible these days.

Larry Holmes · Dec 5, 2024

SwampTrac said:
This is good to hear. Fingers crossed theres no plastic in the pan! 4K isnt bad when you think about it, imagine finding a truck with 86K for only 4K. Thats impossible these days.

You're right about the value all things considered. The only items that were never serviced or replaced on this one are the starter and the alternator. About everything else has so the original $16K+ cost was paid to the bank and now I've almost paid that much again to the mechanics and the parts stores. Not bad for 20 years of service so far and maybe another 10 if lucky. If the replacement engine is sound when it arrives, I'll also swap the recently replaced timing chain tensioners and the metal thermostat housing from the 162K mile veteran engine.

Larry Holmes · Thursday at 3:23 PM

I put the used engine on the stand and swapped a few parts from the original engine. It was a relief to see the timing guide cassettes still intact upon inspection although the donor vehicle was not well maintained judging from the plugs in it. Pulling the old one now.View attachment 5682

cadman777 · 2024-12-20T07:57:13-0500

Larry Holmes said:
I put the used engine on the stand and swapped a few parts from the original engine. It was a relief to see the timing guide cassettes still intact upon inspection although the donor vehicle was not well maintained judging from the plugs in it. Pulling the old one now.View attachment 5682

NIce and clean!
If it was mine, I would change everything that may need changing in the future, if it wasn't already changed.
Such as, timing stuff, t-stat housing, intake seals, front and rear main seal if showing any signs of leaking, etc.
It's out, so might as well make it reliable.

Larry Holmes · 2024-12-20T09:48:31-0500

cadman777 said:
NIce and clean!
If it was mine, I would change everything that may need changing in the future, if it wasn't already changed.
Such as, timing stuff, t-stat housing, intake seals, front and rear main seal if showing any signs of leaking, etc.
It's out, so might as well make it reliable.

The only signs of leaks on the donor engine are the right valve cover which was damaged in shipping and handling and I’m swapping it from the original. Also changing the lower oil pan gasket for the same reason. I don’t expect to see anything in the pan since the timing guide cassettes are intact but I still want to see for myself. Otherwise it’s going in tomorrow. After a short run with the new oil and maybe a flush I’ll change the oil out again.

Larry Holmes · 2024-12-20T11:18:05-0500

On second thought I’m going to replace the rear main seal tomorrow before the engine goes in. It’s a quick and relatively inexpensive fix to prevent any eventual leak. Total cost of tools, parts, and labor is right at $4K.

cadman777 · 2024-12-20T11:51:50-0500

Larry Holmes said:
The only signs of leaks on the donor engine are the right valve cover which was damaged in shipping and handling and I’m swapping it from the original. Also changing the lower oil pan gasket for the same reason. I don’t expect to see anything in the pan since the timing guide cassettes are intact but I still want to see for myself. Otherwise it’s going in tomorrow. After a short run with the new oil and maybe a flush I’ll change the oil out again.

If you need it, then you need it!
How many miles on the engine, and where did it come from?

Larry Holmes · 2024-12-20T22:26:34-0500

cadman777 said:
If you need it, then you need it!
How many miles on the engine, and where did it come from?

I got the engine from remanns dot com. Was advertised as ~86K miles in A1 shape inspected and pressure tested, shipped from Portland. It was built June 2003 about 4 months before the original engine was according to OEM stickers on it and identical so probably from a later 2003 or early 2004. When I didn’t take their quote for a remanufactured long block they sent me the offer for this one. The inside of the oil pan had their yellow chalked inventory number so they did inspect it fairly well. A neighbor referred me to the mechanic who’s doing most of the heavy work. While he’s been pulling the original I’m preparing the donor engine for him to drop it in.

cadman777 · 2024-12-21T18:19:05-0500

Nice find.
It's hard to find an honest 'mail order' engine seller these days.
Best of success in this 'restore'!

2004 XLT at the Crossroads

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