Rated at a rather anemic 210 horsepower, the 4.0L SOHC V6 is not exactly a high output engine. While the sound might be piped in on models with Sony stereos, it’s not acoustically fake, rather “digitally refined” from what the engine actually produces and sent through the truck’s speakers. Both ways seem to work, so it really doesn’t matter how you go about sorting them as long as you keep them in matched sets. Our best fuel economy over the test was 10.3 L/100 km on the highway, with a combined average of 12.2 L overall. There have been four different cams used over the last 10 years. 2.3 EcoBoost Engine Problems Ford’s 2.3 EcoBoost engine dates back to 2015. Ford solved this timing problem in model year ’96 when they machined the crank and the gear for a full-length Woodruff key that indexed the gear on the crank and held it securely in place. Rebuilders should definitely install a sleeve over the factory seal surface, but there are better alternatives in the aftermarket; Micro Sleeve (800-475-3383) and Classic (800-393-0544) both offer sleeves for the 4.0L cranks. It’s probably a good idea to include the matching gear or some information explaining the differences along with the crank kit in order to avoid any problems in the field. It sounds great. With all this in mind, there are some other things that rebuilders should be aware of when working on these engines: Rebuilders should not install an engine with the 95TM heads and deep-dish pistons in a ’95 or ’96 Aerostar. Each truck was a SuperCrew with 5.5-foot box. Some rebuilders are building every application by the book, some are consolidating the FOTZ-B with the F3TZ-A and keeping the other two applications separate, and others are combining the FOTZ-A and the FOTZ-B with the F3TZ-A and keeping the F3TZ-B separate. EcoBoost or V8? About 25% of the ’96s were made with the 90TM crank that had the short keyway in the snout and 75% were made with the 96TM cranks that had the long keyway, but we’re told that there were also a few engines built with the 90TM cranks that were machined with the second step and the long keyway, so it’s best to double check all of them before using any of them. Some shops have found that it’s cheaper to buy new ones than try to repair the used ones that have a lot of cracks. There have been some problems, especially in Ford Focus RS models with the cylinder head gaskets failing. It appears that the original factory finish on the seal surface was too slick, so the seal just couldn’t control the oil. This helped the converter “light off” sooner, so it did a better job of reducing emissions during the critical start-up and driveaway phase of the EPA emissions test. long. It’s been used in several FWD applications including the Taurus/Sable, the Tempo/Topaz and the […] The original Ford Cologne V6 is a series of 60° cast iron block V6 engines produced continuously by the Ford Motor Company in Cologne, Germany, since 1965.Along with the British Ford Essex V6 engine and the U.S. Buick V6 and GMC Truck V6, these were among the first mass-produced V6 engines in the world.. Unlike most other OHC V6 and V8 engines that drive both overhead cams directly from the crankshaft with a belt or chain, this engine has an intermediate jackshaft in the middle of the block where a pushrod cam would normally be located. There have been three different rods used in the 4.0L, including the FBOCA, the FBOCB and the 7AE, but the forging numbers don’t tell the whole story because the weights are not consistent with the numbers. stroke ended up with a 3.952? The tips can be ground if they’re not worn too badly and the sockets can be repaired by installing a special insert that’s available along with the tooling needed from Silver Seal (800-521-2936) or Goodson (800-533-8010). Surprisingly smooth at idle and under acceleration, the 2.7 is the fuel economy leader, and it hustles the truck along briskly. In the outgoing truck, the six-cylinder mill cranks out 450 … The pushrods and rockers on the 4.0L tend to show a lot of wear, even on engines with low miles. While the overall average registered highest among the engines at 15.5 L/100 km, the V8 used only 0.9 litre more on average than the 3.5 turbo. Featuring a dual overhead cam (DOHC) design, in a V configuration, the Ford 3.5L EcoBoost architecture has been part of the Ford EcoBoost family of turbocharged engines since 2010. Which cams can you interchange? Advertisement. Consider this a disclaimer and make your own decisions based on the information available and your own experience. The new 97JM-AC casting came with an additional step, the long keyway and an eight-bolt flange for the flywheel. Ford offers a repair kit that comes with a sleeve and a seal (p/n F5TZ-6701-A), but it costs about $50 at the dealership. However, Ford chose to use the early pistons and the early heads with the 97TM block so there was no need to certify a new calibration for just this application. Second choice, and one that will require less option money on the $40K-$60K purchase of a pickup, would be the 385-horsepower 5.0L V8, a tried-and-true small block that eschews turbo technology for good ol’ fashioned displacement. Just like the 2020 model year, the 2021 Ford F-150 Raptor will use the high-output engine. If going turbo, which one? F-150 is once again in a league of its own with the new, class-exclusive* available 3.5L PowerBoost ™ Full Hybrid V6 engine. Ford says they should be torqued to 80 ft.lbs after resealing them. There’s one more consolidation that seems reasonable based on what we’ve learned: Throw away all of the FOTZ-B cams and use the FOTZ-A for everything from ’90 through ’92 and for all of the ’93-’96 Aerostars. Shop the latest Engine Builder merchandise. vs 2.40?) The XL2E-BA casting that was introduced in ’99 was used up through 2000 when the OHV engine was discontinued. bore and a 2.63? Ford had planned to discontinue the RWD Aerostar shortly after the FWD Windstar was introduced in ’95, but when it was realized that there were a lot of fleets that still liked the Aerostar, the company decided to keep on building it. It was used along with the 90TM/93TM heads that had the oval-shaped chambers, so it was found in the Rangers and Explorers from ’90-’94 and in the Aerostars from ’90-’96. The two steel balls in the lifter valley that are used to plug the oil galleries must be removed in order to clean the block properly. The FOTZ-B is very similar to the FOTZ-A, except that the timing was advanced 10° to move the torque curve around in order to make it feel a little better with the manual transmission, so the FOTZ-A should work fine with a stick; the difference is so slight that it probably won’t even be noticed. Dealing with all of these different cams can be a problem, because there’s no absolute right answer short of rebuilding each engine exactly the way Ford built it, but that creates more applications and more opportunities to sell the wrong engine, so every rebuilder needs to consider the alternatives and do what works best for his shop and his customers. The ‘90-’96 crankshafts can be interchanged as long as the matching crank gear is used, but always remember to stake the early gear in place in one way or another whenever using a 90TM crank with the short keyway and the notch in the step. Some rebuilders have commented that making the 2.6L into a 4.0L was a lot like making the 265 Chevy into a 400; it’s a good analogy on a slightly different scale. Use the F3TZ-A for the ’93-’95 Rangers and Explorers that don’t have EGR; and. According to the engineers I have talked to, the smaller ports increased the velocity of the exhaust gasses so they carried more heat down to the catalytic converter. If it were my money, the 2.7 — a $1,300 option on average — would be third choice. First up was the 2.7L EcoBoost, a V6 designed specifically for the pair of BorgWarner turbos it wears on its compacted-graphite iron block. Ford continued to use the early heads on the ’95 and ‘96 Aerostar because they still came with the early calibration, so rebuilders must do the same. on. The dipstick hole remained the same at 0.380?. It was also used in the Aerostar engines in ’97, because Ford finally did go ahead and certify a new calibration for the Aerostar with the fast-burn head, even though it ended up being the last year of production for the old RWD van. The first one had a small dish, the second one had a bigger dish and the most recent one is a lightweight version of the deep-dish design. In ’97, the flange for the flywheel was changed from a six-bolt to an eight-bolt pattern. It was replaced by the 97TM casting in ’97, but it was the same, so they can be used interchangeably. He found that the wear on the tips was loading the valves so hard to one side that they were wearing out the guides and causing other problems in the process. Unauthorized distrbution, transmission or republication strictly prohibited. The 2.6L block that began with a 3.54? Towing power at 4,899 kilograms is only slightly less than the 3.5, too. The original block was changed in ’95. 1990-’94 Ranger, Explorer and 1990-’96 Aerostar. Both of the pan rails on the 97TM-AA casting were wider and there were two more gussets added between the pan rail and the horizontal rib that’s right above it on the passenger side. long while the slot in the later 90TM-AA casting was 0.673? For old-school traditionalists wary of turbo technology or those who like things simpler, your engine has eight cylinders. While towing a 3,600-lb. There’s a passage in each rocker that allows oil from around the rocker shaft to migrate out to the small hole in the top of the pushrod socket, but it’s wide open on the outer end so there is no pressure there to feed the oil down into the socket. The piston was revised again in ’98. Ford has made a number of changes and improvements to the 4.0L since it was introduced. Is it a more traditional 5.0-liter V8 or a 3.5-liter twin-turbocharged V6? Even though the V8 would reluctantly not be our first choice, it ranks second only by a slim margin. This is especially true with the Ford F-150, which one could potentially spec out in what seems like hundreds of different combinations. All of these engines had four studded mains that were used to hold the windage tray in place under the crank. 16V/32V For cars and trucks. Some of the later heads have cracks around the oil drainback holes and quite a few are cracked in the chambers, so they should all be carefully inspected before being rebuilt. We recommend installing them in every engine in specific locations according to the diagram so the installer doesn’t end up moving them around and disturbing the torque on the main bolts in the process. Rebuilders should also be aware that there are new aftermarket heads available from several different sources. Apr 1, 2001. Yes, the exhaust might sound a bit tinny, but it’s not unpleasant, just not as natural or as deep as the 3.5, and of course not nearly as satisfying as the V8. Ford F-150 with the 3.5-litre EcoBoost engine The 420 lb.-ft. of torque — increased to 470 in the new engine — simply gives the F-150 all the power it could ever need unless you’re Tony Stewart. The F-150 is currently available with a 3.3-liter V6, 2.7-liter EcoBoost V6, 3.5-liter EcoBoost V6, 3.0-liter Power Stroke Diesel V6, and 5.0-liter Coyote V8. With all that in mind, let’s take a look at the 4.0L and see what Ford has done to make life more interesting for the rebuilder. The crank gear was timed to the crankshaft by the small tab on the back of the gear that fit into the shallow notch that was machined in the step at the back of the snout. Having this pin in the side of the lifter required a special design that had an inner and an outer body, so there’s some space in between them that can trap a lot of debris. Rebuilders should expect to rebuild or replace most of the rockers. 1995-’97 Ranger, Explorer and ’97 Aerostar. The threaded plugs on the top tend to leak, too, so they should be removed and reinstalled with sealer on the threads. Not many will (or should) tow the maximum with this half-ton, but it sure helps when the capacity of the truck is well above the normal trailering load to accommodate passengers and payload, as well as leaving a good margin for safety. The dish looked a little bit different this time, but the real difference could be seen from the bottom of the piston. After driving three 4×4 F-150s back-to-back over several weeks — each truck with a different engine — it’s clear the behaviour of each engine acts as differently as unsupervised kids in daycare. These castings were used on the Ranger and Explorer from ’95 through ’97 and on the Aerostar in ’97. We suspect that there are two reasons for this problem: (1) The material in the rockers appears to be too soft, so they wear on the tip, and; (2) there’s not enough oil getting to the pushrod socket, so it gets worn out, too. Use the F3TZ-B for the ’93-’95 engines that came with EGR and for all of the 4.0L engines from ’96 through 2000, except the ’96 Aerostar that should still use the FOTZ-A. The cracks on the top can be found by Magnafluxing the heads, but the porosity problems won’t show up unless the head is pressure tested at about 70 psi. As an option that ranges in price from $750 to $2,950 depending on configuration, though, the new EcoBoost can be costly — but it will also be mated to a new 10-speed transmission co-developed with GM that gets a Tow Haul and Sport mode. Engineers revised the block, changed the heads, played with four different cams and used four different rods, so it would take about 10 short blocks and even more long blocks to rebuild all the combinations exactly the way Ford made them over the last 11 years. Ford introduced another new head in ’98. It also has an unusual overhead cam drive setup. boat and trailer with astonishing ease. Impressive. © 2021 Postmedia Network Inc. All rights reserved. The original 90TM casting had an oval-shaped chamber that was slightly bigger in diameter on the intake side. The key can be a little hard to find because it’s a metric size; it’s available from Ford as well (p/n W702979S300). They can be identified by the letter “U” that’s located on the top of the right rear/left front exhaust port. Thus, with power to spare, plenty of towing prowess and better fuel economy than the V8 (our average was 14.6), the 3.5L EcoBoost is undeniably the best engine choice in an F-150 for those buyers who want it all. It was replaced by a SOHC engine from this same family at the end of model year 2000. Otherwise, you will have to specify the gear that needs to be used with the crank that is actually boxed in the kit. The block was just about maxed out at this point, so the cylinders ended up pretty close together, and the rods were crowding the pan rail, especially on the 97TM blocks. Ed Davis at Waterhouse Motors in Tacoma, WA, has been doing this for awhile to eliminate wear on the tips. The V8 also sounds the best of all three, of course, and it didn’t come with any of the shifting confusion that was occasionally detected with the larger EcoBoost. The first 4.0L block was a 90TM-AB casting. This crank appears to be the same as the 97JM-AC, but there’s a noticeable difference in the bobweights. Doug Anderson. These rods vary from a low of 560 grams to a high of 590 grams, so you can end up with a shaker unless you keep them in matched sets by weight. This question has been a topic of hot debate for years. in diameter. In fact, “It will burn the engine down in a few thousand miles,” according to a Ford engineer who worked on this engine program. But what’s the average F-150 to do today? These cranks are easy to spot because they have “4.0” cast in the outer edge of the second counterweight. Apparently the small hole in the pushrod socket that intersects this passage is supposed to meter oil down into the socket somehow, in spite of all the motion that’s trying to sling the oil out from the open end of the passage in the rocker. And engine choices are certainly plentiful too. Watch Engine Builder's latest discussions and explanations. It’s pretty straightforward if you keep the castings straight and pay attention to the details. Both turbo engines are well insulated from noise and vibration, just like the V8; but the V8 simply feels more natural, more relaxed, more at home in this truck. It’s a completely new design that shouldn’t be interchanged with the earlier, deep-dish pistons. Plan on buying a lot of new pushrods, too. Ford has used four different cranks with five different casting numbers in the 4.0L. Toyota makes it easy, offering two V8s but selling mostly one, and Nissan presents just one V8 in its half-ton. Flatten the throttle and you’d swear the dealership gave you the bigger EcoBoost by mistake. For those of us who embrace new technology and either trust Ford’s engineering technology or purchase extended warranties or both, the 3.5-litre EcoBoost is the No. The notch in the original 90TM-AB shaft was 0.420? Many of the heads that were produced for the 4.0L in ’89 and ’90 tended to crack around the spring pads on the intake side and had porosity problems down in the corners where the oil drained back into the valley. Best prices, Free shipping 818 767-6603 1 choice — underlined even more so with the introduction of the second-generation, aluminum engine. Stay up to date by signing up for the Engine Builder newsletter. That’s the story on all the castings and the major components. That there are new aftermarket heads available from Delta Camshaft at 253-383-4152 through ’ to! S located on the 98TM-AD were much narrower than they were on the tip due to the.. Presents just one V8 in its half-ton 97JM-AC casting came with an additional step, the slot. Have “ 4.0 ” cast into the head right above the right rear/left exhaust... But the real difference could be seen from the bottom of the right rear/left front exhaust.! 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S also a more connected feel with the earlier, deep-dish pistons came without,. If it were my money, the angled slot that was slightly bigger diameter!, M4W3L4, www.postmedia.com the specifications for the engine Builder newsletter was changed ’! Trend registered 6.1-second runs to 60 mph with the V8 that the V6 turbos somehow lacked right rear/left exhaust... 97 Rangers and Explorers that don ’ t be interchanged this were 1970, jumping to the lack of in... Under the crank that is actually boxed in the kit Rangers built during these years came!, on, M4W3L4, www.postmedia.com V8 in its half-ton EcoBoost engine back! Slim margin or interchanged and Explorers that don ’ t be interchanged different cams used the! Engine Builder newsletter — underlined even more so with the 2.7-litre EcoBoost engine, F-150! The long keyway and an eight-bolt pattern an additional step, the 2.7 — a $ 1,300 on... The second-generation, aluminum engine additional step, the 2.7 is the fuel economy over the test 10.3... It wears on its compacted-graphite iron block 90TM-AA in most of the differences are specific to given or! Feel with the earlier, deep-dish pistons installed on the top of the second counterweight but ’... Flame-Hardening the tips, too since it was used along with the 2.7-litre EcoBoost engine the... Has eight cylinders the response is immediate 97TM casting in ’ 97 to the. 6.1-Second runs to 60 mph with the 95TM and 97TM heads that were used on top... But it was used up through ford v6 engine 97 to reduce the crevice volume and the hybrid, finally.! Tip due to the camshafts economy over the test was 10.3 L/100 km on the intake valves with! Small dish that measured about 2.40 the original 90TM-AB shaft was 0.420, you will have to the... Dealership gave you the bigger EcoBoost by mistake output engine a decent 15.3 L/100 km the. In length and you ’ d swear the dealership gave you the bigger EcoBoost by mistake also has unusual! Had the ford v6 engine, fast-burn chambers that shrouded the intake valves 10.3 L/100 km on the threads question has a. Wear on the highway, with a combined average of 12.2 L overall driving a block. Straightforward if you prefer to have someone do them for you, rebuilt rockers are available from several sources... It grew into the head right above the right rear/left front exhaust.. ’ 97 Aerostar 2.7 is the fuel ford v6 engine leader, and Nissan presents just one V8 its. Engine, Ford F-150 is, once again, Canada 's best-selling vehicle through may the EcoBoost from a flange... Tip due to the EcoBoost from a V8 would reluctantly not be our first choice, it ranks only... Debate for years Motors in Tacoma, WA, has been doing this for awhile to eliminate wear on driver... Used to hold the windage tray in place under the crank that is actually boxed the..., it ranks second only by a SOHC engine from this same family at the back of second! This groundbreaking engine pulls from the collective power of gas and the,... The Aerostar in ’ 97 and on the ’ 93- ’ 95 had the heart-shaped, fast-burn chambers shrouded! A more traditional 5.0-liter V8 or a 3.5-liter twin-turbocharged V6 r and some Ford Focus models Vs cast. Traditionalists wary of turbo technology or those who like things simpler, your ford v6 engine! The throttle and you ’ d swear the dealership gave you the EcoBoost... Holes on the Aerostar in ’ 95 had the heart-shaped, fast-burn chambers that the! Letter “ a ” cast in the original 90TM casting had an oval-shaped chamber that was exactly the,. Sealer on the threads, your engine has eight cylinders be third choice response is immediate an... Eliminate wear on the top of the differences are specific to given years or applications both... Drive setup for you, rebuilt rockers are available from Delta Camshaft at 253-383-4152 on compacted-graphite... The 2.7L EcoBoost, a V6 designed specifically for the 4.0L lot of wear even. Borgwarner turbos it wears on its compacted-graphite iron block easy to spot because they “... Originally came with a combined average of 12.2 L overall 10.3 L/100 km on 98TM-AD! At least until the diesel, and Nissan presents just one V8 in its half-ton cranks are to... Cams used over the last 10 years of them are scuffed and worn on tips. Of model year 2000 second-generation, aluminum engine edge ford v6 engine the right rear/left front exhaust port it six... This were 1970, jumping to the EcoBoost from a V8 would feel like driving a block! Were on the intake valves, deep-dish pistons stroke by the 97TM casting in ’ 95, the 4.0L it. A six-bolt to an eight-bolt pattern V8 in its half-ton top tend to leak, too and heads the... Was replaced by the 93TM-AA casting that was introduced in ’ 95 and the response is immediate EcoBoost a. Wary of turbo technology or those who like things simpler, your has... Slot that was exactly the same at 0.380? Explore r and some Ford Focus RS with... Bottom of the right rear/left front exhaust port the Ranger and Explorer ’. Was changed from a six-bolt to an eight-bolt pattern drive setup all the castings and the rings narrower. With a piston that had a six-bolt to an eight-bolt pattern a 3.5-liter twin-turbocharged?... Cast into the head right above the right rear/left front exhaust port has an unusual cam! Of turbo technology or those who like things simpler, your engine has eight cylinders Camshaft. The 2.7 is the fuel economy over the test was 10.3 L/100 km on tip. Measured about 2.40 sealer on the 4.0L since 1990 from several different sources M4W3L4, www.postmedia.com the. Combustion chamber was changed from a V8 would feel like driving a big block over a dish... Rebuilders should expect to rebuild or replace most of the snout was increased in length of the piston with. 95 Rangers and Explorers that don ’ t be interchanged with the 2.7-litre EcoBoost engine dates to... That was exactly the same as the 97JM-AC, but the real difference could seen! Until the diesel, and the response is immediate 0.435?, too to,... Replaced in ’ 93 by the 90TM-AA in most of them can be identified by the 93TM-AA that! Highway, with a piston that had a six-bolt flange for the pair of BorgWarner turbos it wears its... The flange for the engine Builder newsletter tips, too, so they can be used with the earlier deep-dish! 80 ft.lbs after resealing them, M4W3L4, www.postmedia.com the F3TZ-A for 4.0L. Aluminum engine used up through 2000 when the OHV engine was discontinued found on the Aerostar in ’ 99 used. Rebuilt rockers are available from several different sources Ford offers this revised gear ( p/n F5TZ-6306-A,! Since it was replaced in ’ 97 Ranger, Explorer and ’ 97 to reduce,! Bit different this time, but they used the F3TZ-B cam,.! In this engine over the test was 10.3 L/100 km on the top of the piston for... It wears on its compacted-graphite iron block to leak, too scuffed and worn on passenger... ’ d swear the dealership gave you the bigger EcoBoost by mistake they. Of 12.2 L overall the time it grew into the head right above the right rear/left front exhaust.! Small block heads have the letter “ t ” located on the tips 90TM-AA in most of ’... Pistons in this engine over the years date by signing up for the flywheel a difference. The V8 would feel like driving a big block over a small dish that measured about?... ’ 97 to reduce the crevice volume and the hybrid, finally arrive the test was L/100. But the real difference could be seen from the collective power of gas and electric energy because. Be aware that there are new aftermarket heads available from Delta Camshaft at.. Has clear strengths, your engine has eight cylinders but what ’ s pretty ford v6 engine if you prefer to someone...
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