2002 engine rebuild - Page 4 - MustangForums.com



4.6L (1996-2004 Modular) Mustang Technical discussions on 1996-2004 4.6 Liter Modular Motors (2V and 4V) within.

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Old 06-24-2014, 03:02 AM   #31
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It could be that someone was in the engine for some reason and didn't properly torque the cams down. That's the only reason I can think of for the loose bolts, cracked boss/cam bridge, and resulting ejected rockers.

The good news is that even with all the miles and malfunction of this engine, the cylinder walls look really good and there is no wear ridge at the top. We are still probably going to get it bored .020 over.

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Old 06-27-2014, 10:42 AM   #32
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Default Removed the pistons- not good...

Bearing material found on the 1/5 rod journal:



1/5 rod bearings both looked like this:



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Old 06-27-2014, 10:44 AM   #33
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3 & 8 pistons both showed this wear toward the front of the engine:

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Old 06-27-2014, 10:47 AM   #34
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Default Rod journals:

1/5:



2/6:



3/7:



4/8:

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Old 06-27-2014, 10:49 AM   #35
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Default #6 piston, by far the worst. Oil starvation and/or overheating



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Old 06-27-2014, 10:50 AM   #36
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Default #1 piston looked the best of them all



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Old 06-27-2014, 10:52 AM   #37
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There is a dual "flange" behind the center freeze plug on both sides. It makes tilting the freeze plug to get it out a major pain in the ***. The plug bottoms out against the flange and won't tilt. I had to drill a hole in both plugs in order to weaken them so they would bend enough to get them to tilt so I could grab them with my channel locks and yank them out.

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Old 06-27-2014, 11:02 AM   #38
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It's a little ironic that #2 and #6 showed the best compression on the test @ 190 PSI each, given the damage to the #6 piston:

https://mustangforums.com/forum/8384462-post21.html
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Old 06-27-2014, 11:05 AM   #39
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I have all the main bolts (and side bolts) out, I just need to figure out how to get the main caps off. They are in there TIGHT. I'll then be able to remove the crank and inspect the main bearings. After that, I have 2 freeze plugs on the back and some dowels to remove from the block and it's off to the machine shop.
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Old 06-27-2014, 01:00 PM   #40
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I guess it might help if I remembered to back off the jack screws before attempting to remove the main caps. DOH! Oh well, the crank is out. I took some photos but they turned out blurry. The camera keeps wanting to focus through the cylinder and on the floor at stuff there. I'll have to try again and post pics of the main bearings and crank. Once again it looks like the crank took no damage. All 5 main bearings are trashed, with them getting progressively worse from front to rear. This points to oil starvation once again.
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