Engine Replacement Option/Decision

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JediKnight2

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My 06 Limited has been throwing some Bank 1 Timing Retarded codes so I took it into the shop. It has already had the timing chain work done on it with a new oil pump about 2.5 years ago. What they told me is that the oil pressure is reading around 14-15psi and that minimum should be 24-25psi. They said the oil passages are clogged and it's time for a new engine. Their quote with their 3 year 36K warranty on parts and labor is 8K. Fords quote was the same. I have however looked at PowerTrain engines and their engine is 3200 plus my shops 2200 quote to install. I also have a quote from a Ford Mech that will do it with a 3 year unlimited mile Ford engine for 6K.

This truck is in otherwise great shape. Inside and out. I am inclined to drop a new engine as I'm not buying a new car and if I buy another used car I might end up in the same spot anyway. The question is what to go with. The PowerTrain engine addresses some of the 5.4 issues with timing chain guides, phasers and oil pumps. I assume the Ford engine does not address those issues and I would get the same oil pump and plastic timing chain guides I have now.

Suggestions?
 

David E

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Hi there,
Had the same exact predicament myself. Really wanted an Expedition yet all them Triton 5.4 have the same issue.
In my search for a broken one to fix I did significant research into the Engine replacement and found that you can have a re-manufactured engine with the right modification to address the bad design from factory (one would think Ford would take some responsibility for that!)
On another hand I also found out that many who had known of the issue and did their oil changes much more frequent got a very long life out of their engines. (about 2-3k between oil change rather than 5k+).
Fraser engine (top tier) was quoted at - $3350
Jasper Engines supposedly have great quality but not cheap.
Power-source have one for $3149 pretty well assembled and complete.
Its a tough call. I would estimate the rust level and if transmission is solid.
I ended up buying two non-working Expeditions (both 2005) under the notion I will have to change an engine. Found one with bad engine for $300 (Great for parts) and paid $2500 for a non running gamble car... Thinking between the two I can have a great vehhicle for 6k (with the engine replaced.)
I for one rather know what I have in hand. You are right with you fear of a new car... You never really know what you get.
As far as I understood the issue is not with the parts themselves rather then the passageways and clearance for the oil to get to them parts. Issues that is corrected (to some degree) in some re manufactured engines. This along with frequent oil changes should do the trick.
Hope all that above helps.
 
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JediKnight2

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Thanks for the reply! Yes, this company seems to have fixed the 5.4 issues. https://www.powertrainproducts.net/Ford-5-4-Engine-s/803.htm Would probably spring for new exhaust manifolds and stainless hardware for them as well.

If the transmission went, I'd replace that, but it's been ok so far. Rust level is non-existent. It's spent it's whole life in NC off of salt roads.
 

David E

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Thanks for the reply! Yes, this company seems to have fixed the 5.4 issues. https://www.powertrainproducts.net/Ford-5-4-Engine-s/803.htm Would probably spring for new exhaust manifolds and stainless hardware for them as well.

If the transmission went, I'd replace that, but it's been ok so far. Rust level is non-existent. It's spent it's whole life in NC off of salt roads.

New manifolds with suitable hardware is a wise investment. Especial since its not an easy replacement. Il try and call them see if they also offer the rest of the parts that makes this a whole unit. (oil pan etc.) Some sell it as a kit.
Good luck.
 

BlackCoffee

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I have a 2003 Eddie Bauer with a 5.4 and I just dropped about 8 grand to rebuild the engine, transmission, and do some body work. So, I know what you are thinking. The question is whether it is worth spending 6K to have a new engine installed and what may come next. If you are going to put in an engine, get a good idea what the transmission is like, because that would be your next big expense. I had 250k on the transmission and it went out. So, since I had to rebuild the tranny, I also rebuilt the engine. Since the engine is out, consider a new torque convertor. It's only about $150, but replacing it later is $1500 in labor. I don't know your mileage, so I don't know what would go next. Beyond the A/C compressor and clutch most stuff is manageable. I would put the vehicle up on a rack and check for rust/corrosion. Check out the radiator support by the mounts. It holds water and they rust out. The inner and out rocker panels usually go and you don't notice because they are tucked behind the running boards. Also check the floor pan cross members along with a seam just behind the rear wheels. If the body is in good shape, I would say it is worth putting an engine in the Expo.
 

BlackCoffee

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Here is the corrosion around the lower radiator support. You don't notice it unless you are looking for it.Radiator Support-1.jpg Radiator Support-1-2.jpg
 

Hotrod

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I was in the same boat. My 2005 developed a cam phaser issue, estimates from $2,500 for full timing job all the way up to $10K from local Ford service dept for replacement engine (their recommendation). It has 153,000 miles on it and is a cream puff overall with near perfect interior and exterior condition (always garaged CA car). After toiling over what to do I finally made the decision to just replace the vehicle with something that will be more reliable down the road. I ended up going with a 2018 Sequoia, huge improvement over the Expy but that's a different story. Anyway I have my 2005 up for sale, and in the short time it has been for sale the 6 CD changer quit working, the blend actuator for the rear AC started knocking badly, and one door lock has quit operating. I am now so happy I made the decision to replace. I just have the feeling this 15 yr old car is going to continue to have little failures here and there which any one by itself is not that bad and I can fix most, but I lost confidence for those long family vacation road trips. Nothing worse than car troubles while on vacation. So that's my story, now just trying to find someone who wants a project car that looks beautiful for its age.
 

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