Engine replacement

[Foiler]

Had a 460 in a 96 class A go bad this Spring. Leaking and smoking, 2 qts. in 50 miles. Ford doesn't make this motor anymore, everything I have is obsolete. Not just anyone can do a swap in a gasser RV. Not sure of much except that it looks expensive.

At a Ford dealership now, they are evaluating the problem. Pretty sure they will have to overhaul the engine which I assume means removing it, looks like a difficult job.

Not sure if they would put a crate motor from a rebuilder, like Jasper.

Anyone have any experience with this issue?

Thanks,Terry

[TNGW1500SE]

Foiler wrote:
Heard from the dealer and it is going to require a new engine.

Why?

Did they do a compression test?

A cylinder leak down test?

Did they pull the oil pan?

Use a scope to look in the cylinders?

Did they take the valve covers off?

Or what?

Is it smoking?

Is it leaking?

Are the plugs covered in burned oil?


You said it's a low mileage engine and it runs good. I don't understand why it needs a new engine. The dealer can say that but why??? It sounds repairable to me. I'm no expect. Just an old ASE Master Certified Technician that owns his own 10 bay shop that works on 400 (or so) cars and trucks a year 😉

PS: If it does need an engine, Jasper makes a good product but the warranty will vary when you tell them it's going in an RV.

[Foiler]

Heard from the dealer and it is going to require a new engine.

They apparently remove the dog house, all fiberglass, then pull it
up and out the driver door.

It is really expensive but much less than getting another one. So my
plan is to call and tell them to get started. Have a couple of questions for them but my options are limited although, I do have one other possibility.

Will post an update when I find out the plan.

[turbojimmy]

hanko wrote:

How is your running jimmy.

It's running great - thanks for asking! It's still running pretty rich at idle but I haven't really messed with it much. It starts and runs and gets me where I'm going. Can't complain! (knocking on wood...)

[hanko]

turbojimmy wrote:

Foiler wrote:

Has a driver side door but not sure the doghouse will let me pull it out
from the top, maybe with the heads removed, will have to do some
measuring if it comes to that. Don't think there is any way it could come
out the front.

Hopefully you'll find it's an issue that can be fixed with the engine in place.

If the engine does have to come out, hopefully it will come out the doghouse. It was tight, but mine went through the door and through the hole in the floor with the heads on it (valve covers too). The boom for the hoist reached the engine through the driver's side door. I just had to remove the left front tire so the legs on the hoist could get under it.

How is your running jimmy.

[Chum_lee]

Hummmmmmm! Leaks/burns 2 qts. of oil in 50 miles @ 20 years and +-29,000 miles? That's a lot. It's true Ford doesn't manufacture the engine as a complete unit anymore but their OEM website shows that OEM rebuild parts are still available for the 460 in various oversizes. I wouldn't let anyone talk you into a complete engine rebuild unless they can show you major engine components which have inherent major faults or wear. (valve stems, valve guides/seals pistons, piston rings,heads, block, etc.) Those parts are generally fixable by any good engine rebuild shop or available in the aftermarket.

Chum lee

[turbojimmy]

Foiler wrote:

Has a driver side door but not sure the doghouse will let me pull it out
from the top, maybe with the heads removed, will have to do some
measuring if it comes to that. Don't think there is any way it could come
out the front.

Hopefully you'll find it's an issue that can be fixed with the engine in place.

If the engine does have to come out, hopefully it will come out the doghouse. It was tight, but mine went through the door and through the hole in the floor with the heads on it (valve covers too). The boom for the hoist reached the engine through the driver's side door. I just had to remove the left front tire so the legs on the hoist could get under it.

[Jagtech]

460 leaking and smoking at 29,000 miles? Sounds like maybe a set of valve stem seals and perhaps bottom end crank seals might rectify that. At worst, head gaskets. Have you done a compression test (wet and dry)?


on edit: a stuck oil pressure relief valve will cause exactly what you describe. As will plugged oil return galleries on the heads. Both are a relatively easy/cheap fix.

[Foiler]

Thanks to everyone for their responses.

This is a Rexhall Aerbus that we bought new, only has 29,000 and change
on it. Is in really good shape as far as the coach goes, indoors much
of the time. Never been hot and the OP has not changed since new. Always
run synthetic oil in it.

Has a driver side door but not sure the doghouse will let me pull it out
from the top, maybe with the heads removed, will have to do some
measuring if it comes to that. Don't think there is any way it could come
out the front.

Son-in-law is a mechanic but his shop is not set up for this operation,
he has had good luck with Jasper motors in a number of applications. He
is also a customer with O'Reilly's so might be able to work through them.

Will let you know when I find out anything.

[db7512]

What is the mileage on the engine?

[Hideout17]

If you pull engine out do a full overhaul. A good builder can put correct parts in for rv application plus maybe give some extra Hp. Do this if you plan on keeping it. If not keeping it trade it as is. Motor work won't increase value much.

[mike_brez]

turbojimmy wrote:

gbopp wrote:

hanko wrote:
there was a fellow here about a year ago that swapped out a 460. came out through the front, and he did it at an abandon gas station. Seemed like quite a job. I wish I could remember the guys name. Maybe he will see this and respond, good luck

I think this is the one you're talking about: My Repower Adventure.

Good one, but that's not the one. I wish I could remember the guy's name, too. It was indeed at an abandoned gas station and I remember it got flooded.

Mine came out the driver's door. If yours doesn't have a driver's door things get quite a bit more complicated. It's the labor that's killer, which is why I did it myself. I found a used crate engine for $1,000. Figure another couple hundred bucks in incidentals (fluids, hoses, random stuff).

This one

[rgatijnet1]

Depending on the mileage, you may have a problem that does not require an engine replacement. A valve seal problem can cause an excessive amount of oil burning as well as a few other things.
The shop should do a complete inspection of the engine rather than just say you need a new engine and ask you for a blank check.
You may only need to remove the heads and have then rebuilt. You may also have some failed gaskets and seals that need replaced. All of those are a lot cheaper, and more probable, than a worn out engine.

[crasster]

Have you checked at autozone for a replacement or remanufactured motor? They have a lot of options there. Also check Oreilly auto.

[turbojimmy]

gbopp wrote:

hanko wrote:
there was a fellow here about a year ago that swapped out a 460. came out through the front, and he did it at an abandon gas station. Seemed like quite a job. I wish I could remember the guys name. Maybe he will see this and respond, good luck

I think this is the one you're talking about: My Repower Adventure.

Good one, but that's not the one. I wish I could remember the guy's name, too. It was indeed at an abandoned gas station and I remember it got flooded.

Mine came out the driver's door. If yours doesn't have a driver's door things get quite a bit more complicated. It's the labor that's killer, which is why I did it myself. I found a used crate engine for $1,000. Figure another couple hundred bucks in incidentals (fluids, hoses, random stuff).

[gbopp]

hanko wrote:
there was a fellow here about a year ago that swapped out a 460. came out through the front, and he did it at an abandon gas station. Seemed like quite a job. I wish I could remember the guys name. Maybe he will see this and respond, good luck

I think this is the one you're talking about: My Repower Adventure.