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Engine assembly

Tiny
ARIANADANIELLE5345
  • MEMBER
  • 2003 FORD EXPLORER
  • 4.0L
  • V6
  • 2WD
  • AUTOMATIC
  • 208,264 MILES
Hi,

I was wondering if you could tell me the instructions in sequential order for bottom end assembly. I have the vehicle listed above xlt. With a 4.0 v6 sohc engine.
Thursday, June 17th, 2021 AT 7:15 AM

91 Replies

Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,896 POSTS
Hi,

Do you need the directions for replacing the crankshaft, bearing, and so on or the directions for removal of the engine as well?

Regardless, when you remove the crankshaft, the timing chain needs to be removed first and the transmission will also need to be removed.

When I look up "engine disassembly and assembly, " it provides two separate sections. I am going to provide section 2 which seems to be more related to the crankshaft, timing chain, rod bearing, crank bearings, and so on. It does include removal of the cylinder heads and pistons, but if you are not doing them, skip over that section.

There are a lot of steps to this, so don't be overwhelmed. Also, it would be much easier with the engine fully removed from the vehicle.

Let me know if this helps or if you have other questions.

Take care,

Joe

See pics below. Note: This is section 2 of 2 disassembly and 1 of 2 reassembly.
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Friday, June 18th, 2021 AT 8:04 PM
Tiny
ARIANADANIELLE5345
  • MEMBER
  • 323 POSTS
I already disassembled the entire engine, heads and all. I had the block honed and decked and now they are working on the heads. I have the short block back now so while I wait I figured I should put the bottom end back together. So thank you very much for the instructions. They are very much appreciated.
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Saturday, June 19th, 2021 AT 1:25 PM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,896 POSTS
Hi,

You are very welcome. When you said bottom end, I wasn't sure exactly what all was needed. I'm glad that helped.

If you need the other information, let me know. There are a ton of pics that go along with the directions, so they may help you.

Take care,

Joe
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Saturday, June 19th, 2021 AT 8:09 PM
Tiny
ARIANADANIELLE5345
  • MEMBER
  • 323 POSTS
Two of the bearings are chipped. That means I have to get new ones, right?
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Sunday, June 20th, 2021 AT 5:42 PM
Tiny
ARIANADANIELLE5345
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  • 323 POSTS
They were brand new. First one is on the block second one is on the cap.
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Sunday, June 20th, 2021 AT 5:58 PM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,896 POSTS
Hi,

I wouldn't use them. Can you tell the place you got them from they were damaged when you opened the box?

Joe
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Sunday, June 20th, 2021 AT 7:56 PM
Tiny
ARIANADANIELLE5345
  • MEMBER
  • 323 POSTS
I wish I could, but that would be dishonest. I dropped them. I have to pay for new ones, but at least now I know that I need to be 100 percent prepared first by having everything laid out and within reaching distance so I don't drop anything trying to find the assembly lube.
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Monday, June 21st, 2021 AT 11:29 AM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
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Hi,

Based on your response, I know I would like you. LOL. There aren't too many people like you anymore.

Let me know what I can do to help on my end.

Take care,

Joe
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Monday, June 21st, 2021 AT 9:48 PM
Tiny
ARIANADANIELLE5345
  • MEMBER
  • 323 POSTS
Thank you, I appreciate the kind words. Sorry for the late response. My neighbor came and drunkenly tried to install my pistons while I was asleep and of course scratched everything and installed them with no oil in the wrong spots with some facing the wrong way. So I had to start all over and purchase everything all over again. I just installed my pistons. For the connecting rods I can reuse them if I change the bolts and nuts right? And for the balances shaft will I need new bearings or just a whole new balance shaft? Also, are there any other parts or bolts that cannot be reused?
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Saturday, August 7th, 2021 AT 8:36 PM
Tiny
ARIANADANIELLE5345
  • MEMBER
  • 323 POSTS
I just spoke to the Ford parts department and they said I’d have to buy a balance shaft as a whole. The bearings don’t come separate apparently. $523.00. Is a new one necessary? The bearings are pretty worn, but I can’t afford that anytime soon.
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Monday, August 9th, 2021 AT 3:54 PM
Tiny
ASEMASTER6371
  • MECHANIC
  • 52,797 POSTS
They are correct. That is the only way they are sold.

Yes, I would replace it.

Roy
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Wednesday, August 11th, 2021 AT 4:32 PM
Tiny
ARIANADANIELLE5345
  • MEMBER
  • 323 POSTS
I found some online. Can I just put them on instead of buying a whole new assembly.
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Sunday, August 15th, 2021 AT 8:52 AM
Tiny
ASEMASTER6371
  • MECHANIC
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Yes, you can but you would need to disassemble the engine completely to gain access. Joe posted the procedure for removing the engine for you.

If you have it this far apart, you should replace all the bearings, crankshaft, and pistons.

Basically, you will be rebuilding the entire engine. It usually costs more to do this than buy a complete engine.

Roy
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Sunday, August 15th, 2021 AT 2:21 PM
Tiny
ARIANADANIELLE5345
  • MEMBER
  • 323 POSTS
I’m currently on the rebuilding part. I’ve already taken my engine apart and already replaced literally everything under my hood except for the hoses which I will order soon. Because of all of the parts that I bought, I cannot afford to pay $523.00 for a new balance shaft assembly. So I just wanted to make sure that replacing just the bearings wouldn’t ruin anything.
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Monday, August 16th, 2021 AT 12:57 AM
Tiny
ASEMASTER6371
  • MECHANIC
  • 52,797 POSTS
You need the entire unit as an assembly.

By just replacing the bearing, the clearance may be wrong resulting in low oil pressure from the excessive clearance between the bearing and the shaft.

Roy
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Monday, August 16th, 2021 AT 3:40 AM
Tiny
ARIANADANIELLE5345
  • MEMBER
  • 323 POSTS
Darn, that’s a bummer. Okay, thank you very much.
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Monday, August 16th, 2021 AT 12:34 PM
Tiny
ARIANADANIELLE5345
  • MEMBER
  • 323 POSTS
Can’t I just check the bearing clearance with plastiguage to see if maybe it would be fine as is? If so, how would I find the those specifications for my engine? I have looked online and in my Haynes manual, but I don’t see those specs anywhere.
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Monday, August 16th, 2021 AT 4:04 PM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,896 POSTS
Hi,

First, yes I can help you with the specifications. I attached them below. Let me know if that is what you are looking for.

And thanks, Roy, for helping while I was out.

Let me know if this helps or if you need something different.

Take care,

Joe

See pic below.
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Monday, August 16th, 2021 AT 7:52 PM
Tiny
ASEMASTER6371
  • MECHANIC
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Yes, you can but you also need to use a micrometer to be sure the shaft is perfectly round. If it is out of round, it must be replaced.

Roy
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Tuesday, August 17th, 2021 AT 2:56 AM
Tiny
ARIANADANIELLE5345
  • MEMBER
  • 323 POSTS
Thank you, but I need the specs for the clearance of the small balance shaft bearings.
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Tuesday, August 17th, 2021 AT 12:46 PM

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