reluctantmechanic

I have a 2003 5.4 getting close to 220k with almost no problems since new. Love it, runs perfectly.

It's an XLT, and I'm looking to purchase a 5.4 4 door lariat. I'd very much like the 2004-2008 model year - the 4 door version has more leg room than the 2003 lariat, and I can't really afford a 2009.

So here are the questions

1) From what I've read some of the biggest issues are cam phasers, bent rockers, and very small head bolts that break off easily. What am I missing with the 5.4 engine?

2) I'm considering getting a 2004 with a bad engine and swapping in a new one myself...I've done this many times. The question is, if I got a crate engine from Ford directly, will they have addressed the above issues? Is there a company anyone could suggest that upgrades their crate engines and fixes the known problems?

3) I've focused mostly on the engine (since that's likely to be the biggest expense) are their any other problem areas I should be aware of?

Thanks in advance, and would love to hear any ideas or suggestions.

650NutKase

5.4 3v-
phasers, vct solenoids, exhaust manifold leak, timing chain slap, engines built before 09/07 have the old spark plug design that break in the head (get the lisle tool if you get one of these engines), if 4x4 IWE solenoid, FPDM corrosion, 3rd brake light gasket leak. I think that is it...


I like the idea of you getting a new engine and replacing the old. The new reman Ford units have the revisions. Make sure it has a high pressure (melling) oil pump and you should be fine.

reluctantmechanic

thanks NutKase, great info

650NutKase

No problem bud.

Made a small mistake. The head revision date was 10/09/07. The engines made before this date have the old plugs. The ones built after this date have the revised heads with regular plugs.

bourgeois1269

I'd stay away from the 3v if you can but I agree with the whole swapping out motor idea.

diver64

Jasper Engines get good reviews and are several hundred cheaper than Ford Crate. You can take it to a Jasper Authorized Engine place and they can take it from there.

650NutKase

Jasper has been hit or miss from what I've seen lately...

reluctantmechanic

Jasper will not sell me an engine (or transmission). They will only honor the warranty if a licensed Jasper ASE mechanic doe the install...I understand why - some folks could damage it on install. I'd be doing the swap myself to save $$, so Jasper is out.

tomb1269

If jasper is out make sure you are using some of the parts they suggest. Phasers are an oiling issue, factory pump leaks/weeks like crazy, they use a melling:
https://www.youtube.com/watch?v=BUdLPh25c0w
Also be advised that the trany also has a design flaw with the forward drive drum. https://www.youtube.com/watch?v=hrcF...ature=youtu.be