Planning a rebuild (over time)

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aheeejd

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I have an 03 1500 Quad Cab, 4 X 4 with a 4.7. Its got 240k on it now. I've always wanted to rebuild a complete engine (kinda wish I'd done it years ago when I was running Chevy 350's all the time). But I never did & clocks ticking. My truck runs great & is a daily driver. I have it hot oil undercoated for years now, pretty good shape. So my plan is to build a motor, just stock, & hopefully the engine that is in the truck will last. I have about $250 a month to throw at this. All I have now is an engine stand. Would like to hear some opinions on where I should start to look for motor. Junkyard, Craigslist, maybe buy complete junk truck with good motor, pull myself etc.

I know this thread will be slow going but I hope it gets some attention. I mean I'm very mechanically inclined, have swapped motors before, 3 tree tripod lol, but I'd love to get allot of advice & opinions here. I have about $500 right now (cause I got engine stand) & in a couple weeks back up to $750 & so on & so on.

Where would you get/look for an engine??

Thanks in advance. Have a good day!

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aheeejd

aheeejd

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Well, yesterday on the way home from work I was driving 65 to 70, came up a hill, truck decelerated to 60, I stepped on gas & it felt like engine just shut off. Well I mean it did, so I coasted to stop in break down lane, checked some things out. I did the key 3 times to see code & it said "done" which I literally took to mean blown, caput.

So I called triple A, waited & while I was waiting I tried turning truck over, it started up, all gauges reading normal, got out looked around under hood, noticed white smoke from exhaust. Then I noticed no more white smoke, but couldn't hear engine over highway traffic. Got in & looked at gauges, truck off. So driver of tow truck got there, I explain & he says head gasket.

So I have a backup vehicle, a 98 dodge B2500 with a 3.9, so I'm going to drive that, pull the 4.7 & tear it down & send block off to a machine shop & hopefully they can give me advice on what to do. I assume bore it the minimum as I want to keep things slightly low money wise so no big performance build here.

I know this thread is probably quite boring but I do plan on updating it as I go, maybe add some picks as I pull it & tear it down. I'm a first timer doing this so again if anyone feels like making some suggestions they'd be more then welcome.

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JAMMAN

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It might seem like fun, but you are lucky to have 240,000 on a 4.7 without major problems.

I have never completely rebuilt a 4.7, but I've been all over one :)

From what I have read there are like 3 different sizes of crank journal bearings, and some times the wrong ones can be sold to you even from an experienced dealer or on line shop.

You will need head work which you cannot do yourself, you will need a bunch of special tools like ring compressors and plastic gauges and micrometers to read the plastic gauges.

Not meaning to sound discouraging but a dodge 4.7 is not the motor to start on if you want to practice rebuilding.

But if you are brave and have time plus some money to spend it can be rewarding!

Curiosity... how did you get that many miles on it and retain oil pressure? Did you buy it used and someone had replaced motor parts or?? I have only seen a hand full of 4.7's that run at all close to 200,000. Mine will be one but I did heads and oil pump already. Turned over 177,777 today have pics lol.
 
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aheeejd

aheeejd

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Thanks JAMMAN, yeah I pulled over on highway & took pics when it turned 200 000. And yeah, I watched a video on a 4.7 rebuild & the guy talked about the bearing issue. And I do have plenty of time, I work every other week, money, not so much, I figure I got $250 to $300 a month to spend, so that's why I say over a long period.

I guess I assumed that the bearings (journals) would get shaved, so that would change what I'd need anyway, not sure. And bore it out & get next size pistons, I also assumed I'd be buying a new crank. Or if I can get away with turning it. I need to find some books or good info online, library, book store about rebuilding.

As far as how the 240k, I did buy it with 37 k on it & as far as I know it was clean. Motor not touched. I tried my hardest to change oil every 4000. 5 years ago I had hip issues (had both replaced) & I put surgery off for a couple years, so Sullivan tire did all the work that I needed done. At one point they changed plugs & snapped one, had to pull head & have it machined out. So they replaced things like water pump. You know, they were there so replace what you can. And around the 200 k mark my oil gauge took forever to get up to middle, rapping would occur (light rapping) & then would kick in & rapping go away. I spoke to a mechanic friend & he told me to give "hot shots stiction eliminater". Did half a quart every oil change & changed at every 3000 miles just cause of age (miles) & it worked, right up until Monday when broke down. When I started it, oil gauge would snap right up, no knocking at all.

And prior to using the stiction eliminater I drained a quart of oil & dumped in a quart of mystery oil (marvel) & drove around for 45 minutes, then drained, filter, added half quart stiction & rest reg quaker state 5w 30. All suggested by my mechanic friend, at the end the other day, motor sounded like the day I bought it.
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firebirdtony

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4.7
It might seem like fun, but you are lucky to have 240,000 on a 4.7 without major problems.

I have never completely rebuilt a 4.7, but I've been all over one :)

From what I have read there are like 3 different sizes of crank journal bearings, and some times the wrong ones can be sold to you even from an experienced dealer or on line shop.

You will need head work which you cannot do yourself, you will need a bunch of special tools like ring compressors and plastic gauges and micrometers to read the plastic gauges.

Not meaning to sound discouraging but a dodge 4.7 is not the motor to start on if you want to practice rebuilding.

But if you are brave and have time plus some money to spend it can be rewarding!

Curiosity... how did you get that many miles on it and retain oil pressure? Did you buy it used and someone had replaced motor parts or?? I have only seen a hand full of 4.7's that run at all close to 200,000. Mine will be one but I did heads and oil pump already. Turned over 177,777 today have pics lol.
I've got 240 on my 4.7 still good oil pressure and pulls strong. Just blew head gasket myself so I'm also starting my build. Since your engine wasn't oil starved meaning no rod or main bearing issues. You may not have to cut them at all. Unless the numbers come back showing wear. My mustang had 200k and the block didnt even have a ridge on it. So I was able to reuse my pistons but not crank.
 
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aheeejd

aheeejd

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Well, its been allot of thought going into this, allot of reading, watching videos etc. And I've decided to go ahead with the remanufactured engine from accurate engines, http://accurateengines.com

The whole saving up & going slowly, it would take me a year to get it done. I live in New Hampshire & have an hour ride to work, winter coming, 4 X 4. So I'll be pulling the old 4.7 out, taking things I'll need for new nakid long block (oil pan, valve covers, timing cover & accessories).

I work every other week, so hopefully I can get it done within a month + -, hopefully -. Anyone out there do this using accurate engines? If so I'd be interested in asking a few questions thanks everybody

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aheeejd

aheeejd

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Just ordered engine, $2839 total, be delivered Nov 4.

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usaf2006

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Whew that escalated quickly. Sorry you had issues. Hopefully the swap goes easy!
 
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aheeejd

aheeejd

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Whew that escalated quickly. Sorry you had issues. Hopefully the swap goes easy!
Yeah, truck still running when I planned to do this, I guess I should have started it 60K ago or so. I just couldn't take looking at the truck sit there for a year while I drove a purple van with pinkish interior lol. Not kidding. This way I'll be back in truck for the winter

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aheeejd

aheeejd

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Well Fri. Nov 4th came & went & no engine. The guy from Accurate Engines (Tony) calls me Thurs. the 3rd & says I've got good news & bad news. Good news is your engine is done, bad news is we lost it. Said they put 3 engines on a truck & forgot to label them etc. Going to look into rest of day & if can't locate put a rush on another motor for me. So on the 9th I get confirmation & tracking #'s for new engine on the way. Picked it up Fri the 11th. I'm glad I got the engine, & it looks great, but I wasn't impressed with things such as (Tony). I mean 4 times he called to as where the engine was going. 4 times. Second time was whatever, 3rd time was like wow. Fourth time was like this guy is incompetent. Anyways.

I've stripped my motor with what I need off of it. Had a real hard time separating tranny from block. Used a map torch & heated where the pins are located & popped right apart.

Here's some pics of taking out/apart & couple pics of new motor. 8e17c5fa24a6cedb90c84cd0e997670f.jpg7fe93a576e22d1818bd91aa9c9312a4c.jpg10e906e513b5d0abb3a39a873c84cdfd.jpge7393912afb3ebdd4efc1b5ff1a3a3aa.jpg919fe13440aafe99883b337376353192.jpgdb6630dd5fe37e8ce8c0de540b1758df.jpgf0b9c0d9046d164c523ac0d5086cff4e.jpg90daa45854461fc98f3a412a23153ee9.jpgeaa9614923b89270fb4ba03cc1bfc3de.jpg

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aheeejd

aheeejd

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Oh & I also replaced the steering rack, been leaking for years. Was pretty easy & straightforward. Course it was nice that the engine was removed. Very last bushing fell apart. Of course nobody had them so that got put on hold for a day



723783d2acb390e5f1d7f4703f07ecdb.jpgceacd6c77fc03aa7b9d7046a7a8c865b.jpg906406d72977eff22bad58ff08c5e9e4.jpg1179d1861cc97bd9edccaaf7b7c691da.jpg

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Egress

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Stock 235hp 4.7L/287 V-8
I like this thread. I also own an 03 4.7 and currently have 123k. I have never had any major issues and the engine runs strong and smooth. I have thought of buying a new truck but realistically there is nothing wrong with mine. I plan to purchase a new engine to replace mine when the time comes, so everything in this post I will be referencing.
 
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aheeejd

aheeejd

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Another couple strikes against Accurate Engines, (http://accurateengines.com). Went to put on oil pan. Grabbed gasket/windage tray (shipped with motor) & it was bent (see pic). So I ran out & bought another. I put new one on & put several oil pan bolts in just hand tight. You should do this so when you tighten the oil pick up tube bolts so that the gasket stays in line/shape. Don't forget to put oil on o-ring for pick up tube. There's 1 bolt that goes near oil pump. Then 3 lock nuts for rest. All torqued to 20 ft/lbs. And of course Accurate Engines bunged up a set of threads for pick up tube. I got but on but it took a bit.

So course now, I have to get on the phone & talk to Tony, or customer service & try & get $60 out of them for having to buy a new gasket. f1e20dd37939772aca757bb3e338a9f3.jpg

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aheeejd

aheeejd

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I like this thread. I also own an 03 4.7 and currently have 123k. I have never had any major issues and the engine runs strong and smooth. I have thought of buying a new truck but realistically there is nothing wrong with mine. I plan to purchase a new engine to replace mine when the time comes, so everything in this post I will be referencing.
Take lots of pics, make notes, diagrams etc. Huge help putting back together. Also I'm kinda struggling with the gasket package that comes with engine. There are so many. I'm also struggling with cleaning up the surface on the timing chain cover where the water pump goes. No scraping with metal or abrasive, not even scotch brite. I've tried break clean, mineral spirits, permatex brand gasket remover, carb cleaner. Going to try easy off tomorrow.

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aheeejd

aheeejd

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So I was having quite the time trying to get the timing cover clean on the water pump side. Its aluminum so only using plastic, tried a wood wedge, wasn't doing it. Tried mineral spirits, break clean, carb cleaner, nothing.

My sister came over for Thanksgiving dinner, the night before I asked her if she had a can of easy off, cause I didn't have any. So she brought it, I sprayed it on & found some scrap hardwood with some nice razor like edges. Worked great, now I can really start to put this new motor back together.

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usaf2006

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I used a metal gasket scraper when I did my water pump lol... just went very gentle and cleaned with a cleaner when I was done. Sealed great.
 
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aheeejd

aheeejd

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Well I haven't written in a while, been doing a few other things to truck while engine is out, like last night I pulled off front differential cover, cleaned it up, little black paint, new gasket (with light layer of RTV). Getting cold here, last night was around 34°. I should of & wish I had done the front when I had the steering rack out, but, all went well.

Accurate Engines strikes again, I was in the process of putting on exhaust manifolds, I did drivers side first, the passenger side, last bolt to torque down (18 ft/lbs) & it just spun & spun. Stripped out, & not by me. So I took manifold back off & what do I see, some green paint from accurate engines on the exact bolt hole, see pic, d182512577a91e9ab44dbeae2bc415e9.jpg

Top left marks the spot, pretty disconcerting, I hope they did proper work internally. But anyway I went & bought a heli-coil kit came with the heli-coils, the tap & the tool to install the heli-coil. Had to go get a odd size drill bit (thanks for having it in store Lowe's) size is 21/64". The heli-coil kit was size M8x1.25. It actually worked great, able to torque it down no problem.

I also installed a new set of front shocks, shocks that were on it was original, so it was time for sure.

Today is the day, gotta run a couple errands & then hook this bad boy up to the hoist & drop it in. Gotta clean up the dowels on tranny first.

Also if you do anything like this & you have automatic transmission, pull the torque converter, replace the seal, & if on the hub of the torque converter there is an o-ring replace that to. Its actually the transmission oil pump seal.

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usaf2006

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Awesome progress. Can't wait for you to get it running.
 

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