I have about 345k on a 2000 4.6L in an F-150 4x4. No major engine problems until now (previously the worst was 2 blown spark plugs, one each bank), and the current prob is apparently a deep engine issue (bearings and loud noise). I had an independent look and listen and had a Ford dealer do a diagnostic. The dealer does not want to do a repair on such an old engines because so many things could be wrong or go wrong in the future. The recommendation is a replacement, and their Fred Jones reman with around 20 hours labor is pretty steep, and steep relative to the value of the truck. Moreover, that engine would not be fully dressed, and the starter, alternator, and valve covers are about the only components I would reuse. The injectors, throttle body, fuel rail, exhaust manifold, intake manifold, emissions control, etc. are original and old and I cannot see a good reason to use 17 y.o. components on a reman.

I searched the threads for vendors and came up with some resources and found some on my own.

The terms rebuild, reman, and crate get thrown around a lot but mean different things to different vendors. Apparently, no one sells a fully dressed, turnkey 4.6L. (It appears that generally only racing engines are turnkey with a few exceptions).

So far, Powertrain Products of MD has shown me the best deal. The base is $2,400 plus $150 shipping, deferred core charge unless not returned within 30 days, and no shipping charge on core return. Its warranty is 4 years, 1MM miles, with a labor component of $75/hr, and can be upgraded for $350 to 5 years, no fault $100/hr labor component, rental car reimbursement up to $35 per day, and the cost of a tow, if any. Most warranties for remans and rebuilds do not have a labor component. NAPA has an engine for $2,900 with 3 year, 36K mile warranty and labor component capped at $50/hr. So the PP is better than NAPA at a better price (and NAPA will not have any for 3-4 weeks). Precision Engines and ProMar Engines (which sells on e-bay and has been referenced in several threads here) are cheaper, but the warranties are not as good and there is no labor or incidentals like car rental or towing.

I am about to call a Jasper affiliate, I expect a higher price and wanted to hear the others first. Rock Auto does not have any in stock and the price is not available, and I cannot find one on Summit Racing's site either (perhaps I need to call).

One place that buys from Powertrain told me that they would want the deposit for the amount of the engine and would mark it up on me too. They will also mark-up the cost of all the components require to dress the engine out, and suggested a 100% markup and 50% margin on those parts. If they use customer parts they will charge $120 per hour for labor instead of $90, and expect about 20 hours of labor.

I would appreciate any input on:

1. Other vendors I may have missed. Particularly some that may have turnkey engines that are dressed out.

2. How to manage the expense of the dress out items if the best I can get is an engine with equipped with an oil pan, filter, and timing components cover (sans valve covers and injectors, emissions, manifolds, etc.)

3. Should I go against the grain and attempt a repair. No one has torn anything down yet. There is no oil or fluid coming out of the exhaust, but there is a little deposit on the bottom of the oil cap that may be gasoline. So there may be a head and gasket issue. The truck has the Triton tick and I have been planning on replacing the exhaust manifolds and gaskets. I cannot do that extensive repair myself. What is the potential expense and what am I getting into.

 

P.S.--The Ford dealer and I are talking, and they came back with a better price for a Fred Jones reman. But the dress out is still an issue because I can basically re-use the batter, starter, alternator, radiator, air filter, and valve covers. About everything else would need to be replaced and getting that under control is an issue.

A 3 year transferrable warranty on parts and labor and Ford tech knowledge putting it together has some value. At least to me, because I don't know any supermechanics that provide me a ready alternative.

 

For a 2000, I would try to find a good scrap yard engine, I assume you will be doing the work?