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I've never had a bad spark plug in the 40 plus years I've been working on internal combustion engines....till that set of motorcraft's from RA. Maybe it was a bad batch? Can't say but they failing one at a time. Tim

Yup, where did you buy them? I got counterfeit motorcraft plugs a couple years back. Rockauto bite me. Chased a random misfire for a while. It got worse and worse till the plug died. Then another one died and than another. Bought local from parts store....no issues since. Tim

gas tank plug putty......What the? All I've ever used is the O ring https://www.wildhorses4x4.com/early-bronco-fuel-sending-unit-o-ring-seal?srsltid=AfmBOopzpsIlvRo3ZEAfU5CYpCnFLYrvYwSf5cQP3dNMk3BoiAOD5KbW Lube it up with some Petrolium Jelly and install. Tim

Fix all leaks in the fuel system as you find them. Failure to do is is just a Darwin award waiting to happen Tim

IMO, if you had a spun bearing you would NOT have 50-60psi oil pressure. Tim

Roller cam break in is not really needed but to each their own. :) While sound is different to every ear, that does not sound like a rod knock. Rod knocks are a deep sound IMO. Like a big hammer hitting solid. A thud.... To me that sounds hollow....but I am on my phone so.... I would check...

Got my springs at Alexparts.com Don't recall which I went with....It's been a few years.... Tim

This ^^^^^ also Power brakes? My booster diaphragm was leaking causing high idle. Tim

Trust nothing when trying to find this issue. New don't mean good and old don't mean bad.........Same with "restored". Could be Fuel lines Fuel cap Leaking sending unit gasket Canister Expansion tank in the bed behind a cover behind driver seat Leaking fuel pump Leaking fuel line connections...

Sounds like the machine shop did it's job correctly. Nice and tight with in specs. Put it together and run it....... :) You will have very nice oil pressure..... Tim

Explorer cam....what the GT40P's can handle Explorer F4TE-6250-BA Hydraulic Roller Intake at 1.6 rocker ratio .422" lift 256 duration Exhaust at 1.6 rocker ratio .448" lift 266 duration 1.7 rockers is .449 intake and .476 Exhaust 116 lobe separation You need to upgrade springs....... I run this...

New coolant sensor....Hummmm New don't mean good and old don't mean bad. I'm guessing you have a 195 stat due to the temps you listed. I've had many a temp sensor's that I replaces with "new" that has read higher than the old one I took out. My Mach 1 for example. Mechanical reds...

UGH....man.....If you ship it back (on your dime) they could very well say it was just the gasket and YOU were the cause. Then they have your motor and more than likely charge you to ship it back......and charge you to put on a new gasket. BY CHANCE...does it have a "heat tab" on the block...

If it was me I would put a torque wrench on the head bolts and see if they're torqued correctly. I would also be contacting ATK.... I mean crap happens when you rebuild. I had a cracked head and I chased my tail for two months. My head was cracked internal and magnaflux didn't find it...

That head is either cracked or it's not torqued down correctly. You said this is a new build? Tim

I run 2.5 SL and 1 inch BL with 33's.....99% street never has hit...... Tim

My van was super low wear too. I went .020 over.....didn't really need to but I wanted new cam bearings and when at the machine shop...... Tim

That W come from a van? The super long dip stick looks van to me. So does the oil pan. I ask because I had a hell of a time with the stock E7's. One had an internal crack. Machine shop said it was the second one they had seen from a van with that issue. Just watch for bubbles in the...

I went with P's on my 96 w. Yes bad plug angles but they make hp so Tim

It was....mine were OK buy my buddies were retarded. No issues getting new ones Tim