I just rebuilt the top end of my 4.2 and some other small parts while I was in there and it cost me ~$1000.
That was with no labor though, I did it myself.

I agree with 2wd5spd, I think a 4bt would be cool but putting on a new head (or 2) would be cheaper.

 

By the time I get all of that apart and whatnot, I could literally pull the engine, sell it to a local company in Austin that rebuilds blown engines for resale, use that money to get the 4BT. Plus, I don't have much faith for the Essex from all the problems mine gave me before it even had 100K on it (I had to replace the lower intake manifold because it cracked from normal wear and tear). All in all, I've put $4000 keeping a truck running that I bought for $5000 with 67K miles on it.

 

Yeah, I guess for your situation putting in the 4BT is better.
I also am not a fan of the essex.

 

If you can find a 4bt for as much as you could get for a blown 4.2, please send me a link. From what I've seen, you cant get a good, reliable, 4bt with under 200k miles for under $2500. I will agree, that it may be cheaper in the long run, but it may not. My 4.2 has 140k on it and I've never had a major problem with it. I'm not tryin to start a fight or anything over it, I'm just saying that some 4.2s may be great and run forever(like mine) or some may give you problems all the time. I just strongly believe that for most people, it would be cheaper to rebuild the 4.2. Plus if you do manage to get the 4bt to bolt up to the factory ford tranny, how long is it gonna hold up behind a 4bt before you need a new transmission as well? There are multiple factors with which would be cheaper, or better. But I honestly think that for most, it would be cheaper to rebuild the 4.2. Or even drop a carbourated v8 in it like a 351. That would be nice, and a buttload cheaper than the 4bt

 

I've seen some 4bt panel vans sell for $2000 with under 100K on them in Denver and Colorado Springs. Like you said, some 4.2's run forever without a hitch. Mine has had every major replaceable issue before it hit 100K. If you have the M5R2 5-spd, the 4bt bolts right up once you swap the flywheel and everything. Just suggested that a kevlar clutch be added to handle the torque. The M5R2 will handle 380 lb-ft give or take a 10 lb-ft. Basically as long as you don't run an intercooler you should be fine once you get a 3200 rpm gov spring in there and some 190cc injectors and be able to run around 340 lb-ft. I would've put a gasser in when I had all my problems but I had emission laws to deal with saying that since the body was an 02 the emissions equip. had to be that of an 02. Texas doesn't have diesel emissions, at all. The law book on inspection literally has a side note that states that the emissions equipment only applies to vehicles running on gasoline as a fuel. I also run between 10K feet above sea level and sea level quite constantly so carbs are not a good option for me.

 

I'm glad that I live in south dakota where there are no emishion equiptment

 

I think its funny. You can get pulled over for excessive black smoke in a city, but they won't pull you over as soon as your out of the limits. And by excessive black smoke I mean making it to where other drivers can't see.