Episode 6: 1999 GT40P Explorer 5.0L (06/30/2024)
Questions to the good folks in this forum will be colored Purple and are at the end of the post.
Edits will be in
Orange.
It's been a while since I've posted updates so here I go. I really like pictures so as you'll notice, there are many.
TEARDOWN
I should have taken lots of pictures during the process assuming there was some great step-by-step guides specific for the Explorer but sadly, there are not. Yes this has been done many times by folks on here but there is not a guide with a bunch of pictures or videos starting from the tear down to the rebuild to the final assembly. Anyway here is what the engine looked like when I tore it open.
It was pretty caked up with carbon and sludge but once cleaned up - really wasn't too bad.
The biggest PITA in this entire process has been cleaning up all of the parts (without a parts washer). I have spent probably $250 alone in cleaners, degreasers, paint, etc. This is what really has taken the longest time. I painted with Duplicolor Cast Coat Iron and Cast Coat Aluminum.
REBUILD
I do not have pics of several steps but they are not Explorer specific so any Youtube video on the subject will show the details.
1. I removed the pistons and gave them a soak in Berryman Chem-Dip which worked amazing. See below
2. I inspected the cylinder bores - no damage, no bore over, no piston top lip and factory cross hatch still there. I gave them a good hone and medium aggressive cross hatch.
3. I installed new rings on the factory pistons and new bearings on the rods. The pistons and connecting rods had no damage.
4. I removed the factory crankshaft and noticed only typical wear. I have it a good polish with fine grit sandpaper and the shoestring trick.
5. Main bearings showed typical wear with only a few slightly worn down to the goldish color layer. Replaced them all.
6. Inspected the factory camshaft - typical wear, also gave it a good polish with sandpaper and a shoe string. I did not replace the cam bearings as I could not see any wear and I didn't want to deal with the hassle of replacing them.
7. I'm lucky and found a local machine shop to work on the GT40P heads (clean, decked and redid the valve train (new seals, lapping, etc.) He said they were slightly warped so I'm glad I did it. Valves were not burned and there was no reason to replace them. Inspected for cracks - there were none.
8. New water pump -
by the way, why do they not make a new water pump bolt/stud replacement kit? There are none! I'm having the stock valve covers blasted and powdercoated. Also what is that hole for in the top of the pump?
9. Starting to put it all back together trying to remember where everything goes and what bolts go where.
Can anyone tell me where these brackets go?
Can anyone tell me what size plug this - the plug kit I bought only had the big ones?
Can anyone tell me what goes in this threaded hole in the timing cover (the one in the block is for oil sender) and also this threaded hole in the back of the block (right hand pic)?
