To re-engine, or not to re-engine? That is the question

[Bilsto]

I've been thinking about this a lot over the last couple years. My Expedition is in really good shape, everything works, it's a stout truck. The transmission was rebuilt a couple years ago and probably has only about 15,000 miles on it. But, it's approaching 252,000 miles on the original engine. The engine is running fine right now, but I can't expect it to keep going forever. So if it comes down to it in the near future, what would you do? Re-engine, or just buy something newer?

My thought is that what I'd pay for an engine is roughly the same as what I'd pay for a comparable replacement SUV, but I don't know that for sure. Plus, getting a newer vehicle means starting the repair and upgrade process from scratch, which will mean even more money.

I've heard that a replacement Jasper 4.6L engine could cost me about $5,000.00. Anyone here have any thoughts on this, or personal experience?

 

[ExplorerTom]

Keep running what you have. Keep the oil clean and maintenance up to date. The 4.6 2V will go a long time.

 

[Robert Wagner]

I too have been thinking about underwriting a power train overhaul.

A limiting factor, in my opinion, has to be how to address unattainable parts. For example, the discontinued fuel tank. Being made of plastic, they are developing cracks in their old age. Consequently, the tank will fail its evaporator test which, in my part of Texas, can prohibit the vehicle's registration's renewal. I understand there are ways to game the aforementioned system and the issue becomes moot once the vehicle reaches age 25 (as Texas then waives the emission test) but what would one do if the tank's developing cracks advance to the point where fuel leaks (as opposed to just fuel vapors)?

Trying to develop/research a "get well plan" for my Expedition is a primary reason why I joined this forum as it may provide insights into what other issues are in store for my decades old ride.

 

[Bilsto]

Keep running what you have. Keep the oil clean and maintenance up to date. The 4.6 2V will go a long time.

Oh definitely. I'm just considering it in light of catastrophic engine failure one day. I wouldn't consider a preemptive swap.

 

[Bilsto]

I too have been thinking about underwriting a power train overhaul.

A limiting factor, in my opinion, has to be how to address unattainable parts. For example, the discontinued fuel tank. Being made of plastic, they are developing cracks in their old age. Consequently, the tank will fail its evaporator test which, in my part of Texas, can prohibit the vehicle's registration's renewal. I understand there are ways to game the aforementioned system and the issue becomes moot once the vehicle reaches age 25 (as Texas then waives the emission test) but what would one do if the tank's developing cracks advance to the point where fuel leaks (as opposed to just fuel vapors)?

Trying to develop/research a "get well plan" for my Expedition is a primary reason why I joined this forum as it may provide insights into what over issues are in store for my decades old ride.

Wow, I didn't know that about the tank. I guess your only option there is a fuel tank refurbishment. There's gotta be someone who can do that.

Glad we don't have vehicle inspections and tests in my county.

 

[Dan Faoro]

I went through this a few years back on my 2009 F-150 with the 5.4. The truthk had at that time 185,000 miles on it and it was having cam phaser issues which were repaited once and then it threw a rod. I had several courses of action. Do a head job, which may or may not fix everything, install a Jasper long-block for around $6,500 or install a new factory Ford long-block for right at $10,000. I opted for the Ford engine which came with a full one year warranty. The truck was in such great shape it was worth. I'm now at 225,000 miles and original transmission, all going strong.

 

[Tocapet]

Keep running what you have. Keep the oil clean and maintenance up to date. The 4.6 2V will go a long time.

Second that... My son-in-law has my '03 F150 4.6 that I sold him 7 years ago. He has almost 300K on it now and it still runs fine. I think the 4.6 is the better engine.

 

[Robert Hill]

Had need to replace 5.4 engine on my 98 EB at 156k; the shop found a replacement with 114k miles; they also installed a new radiator, hoses, water pump plugs and oil cooler. Cost was about $5100. The replacement engine has been flawless after 12k miles so far.

 

[brhulen]

I recently saw a 4.6 out of a 1998 Mark VIII for sale and was wondering if that is a possible transplant for the 97 Expedition with the 4.6?

 

[Yupster Dog]

I recently saw a 4.6 out of a 1998 Mark VIII for sale and was wondering if that is a possible transplant for the 97 Expedition with the 4.6?

There are 2 different 4.6 engines. Romeo and Windsor.

You can tell the difference by a big R or W on the block somewhere.

They would both need to be W or both R for a quick swap.

 

[Eric in Wyoming]

Bruh - our '97 5.4 EB 4x4 just pulled a 5x8 enclosed trailer full of camping gear from Jackson Hole WY, through Yellowstone National Park, to I-90 in Livingston MT, and we're currently staying in Dickinson ND for a couple days. We tripped 304,000 miles along the way. You got plenty of time to hunt down another engine.

I'm in the same boat, really - thinking about getting a later model PI engine to freshen up and have ready for when something major happens to this one. But then I'm also thinking line boring the block, gapless rings, ceramic-coated bearings, main cap & head studs, helicoil all the spark plug threads before one has the chance to blow, Lightning/Harley cams....

 

[Robert Wagner]

@Eric in Wyoming "getting a later model PI engine" I am too new to this forum to decipher the "PI" in PI engine. Could I trouble you to enlighten me here? (Wild guess police interceptor...)

 

[Bilsto]

Bruh - our '97 5.4 EB 4x4 just pulled a 5x8 enclosed trailer full of camping gear from Jackson Hole WY, through Yellowstone National Park, to I-90 in Livingston MT, and we're currently staying in Dickinson ND for a couple days. We tripped 304,000 miles along the way. You got plenty of time to hunt down another engine.

I'm in the same boat, really - thinking about getting a later model PI engine to freshen up and have ready for when something major happens to this one. But then I'm also thinking line boring the block, gapless rings, ceramic-coated bearings, main cap & head studs, helicoil all the spark plug threads before one has the chance to blow, Lightning/Harley cams....

Wow, you've got grander designs than me! Good to know you're up to 304k. Maybe I'll get there too.

 

[Eric in Wyoming]

@Eric in Wyoming "getting a later model PI engine" I am too new to this forum to decipher the "PI" in PI engine. Could I trouble you to enlighten me here? (Wild guess police interceptor...)

I thought the same thing too at first. In 1999, the 5.4 got a few upgrades to address some initial issues. The spark plug holes were beefed up to reduce the risk of blowing a plug through the hood(six threads instead of four), and the combustion chambers were reworked from an open-chamber to a closed-chamber. There are other changes as well, but in the end they bumped power up from 230 to 260.

The PI means "Performance Improved", or something to that effect.

 

[Robert Wagner]

I thought the same thing too at first. In 1999, the 5.4 got a few upgrades to address some initial issues. The spark plug holes were beefed up to reduce the risk of blowing a plug through the hood(six threads instead of four), and the combustion chambers were reworked from an open-chamber to a closed-chamber. There are other changes as well, but in the end they bumped power up from 230 to 260.

The PI means "Performance Improved", or something to that effect.

Thanks!

 

[Yupster Dog]

helicoil all the spark plug threads before one has the chance to blow,

This is not needed as long as spark plugs are tightened properly. They always blow after they have someone change the spark plugs. The main plugs to go are cylinder 3 and 4 both the hardest to change so they don't get tightened properly. Not a coincidence.

Would the PI stand for police Interceptor?

 

[Samuel Jewell]

I thought I'd chime in on this due to my recent financial blow! Last may, I blew the transmission and was faced with a choice of scrapping a nice truck that I liked or forking out $2K for a trans rebuild. I chose the rebuild and told the GF then, "well, I'm obligated to a motor now. Too much to walk away" This spring my 297K 5.4L gave up the passenger's side cam.

HS buddy of mine has a shop and found me a 115K mile motor. Motor, installation, new gaskets, water pump, radiator, hoses, PS pump, upper and lower ball joints and new sway bar links. Total bill, $5,200. Then it needed new tires so ~900 for a set of new BFG AT's. So now, counting original purchase price of $2500, I have a $10,600, 23yo truck with a high retail value of ~4k.

If I went to buy a replacement then I'd spend ~10K on something equivalent that I would have absolutely no clue about any of that and potentially would be making payments on a new rig AND any of the above repairs.

Good Lord willing, all of my debts will be paid off in 5yrs, house included and then I'll think about a newer ride! (if you wanna hear God laugh tell him your plans).

 

[Machete]

Well I found some early rust on the bottom seam of my passenger front door. ****** me off. Alreayhave some popping out on rockers.
That makes my decision easy.

Next high ticket item that goes I’ll fix and sell.

Wouldn’t mind finding another Eddie Bauer 4x4 that’s rust free as replacement.