2004 5.4l 3v Camshaft scoring
 

I replaced my whole timing set 60K ago with Cloyes timing kit but a Ford camshaft phasers. Truck now has 275K. Well the last few week I've been getting codes and such then finally just no power. Tore apart my front end and valve covers to discover that the chain guides had broken apart inside and one of the tensioners had failed. The chain chewed up the tone ring and dug into the oil pump. Needless to say there were broken pieces of plastic and metal in the oil pan when I took it down yesterday. I never saw any metal in the previous oil changes or when checking oil. After taking off my cams yesterday to start the timing process, I see horror on my cam tower, camshaft and cam caps.

Is my engine shot? Do I have to get a new head? How about a new camshaft and caps? I don't know what to do.

Thank you,

Ken

I would rebuild it only if the truck is in good working order.

Do you mean the whole engine or just the head?

Thank you!

Ken

The engine.

Why would the whole engine have to be rebuilt?

Thank you!

Ken

Just to be sure anything else didn't get damaged. The reason you didn't see any metal was because the oil filter was doing it's job. Before it gets to the filter, it is passing through other components. The cams are on top of the engine, and as the oil is washing down back to the pump it is hitting other sensitive areas.

The other problem with scoring is the metal particulates are small and acts like an abrasive sand on other components as well that have a lesser hardness.

Up to you, but if it were my engine, I'd yank the engine and have it dismantled and gone through.

I totally understand and appreciate your input. It just tears me up to no end that I replaced all of the timing set and OEM phasers 60K ago along with a new oil pump, lifters and rockers. And this is what happens when I tried to save a few bucks on a the timing set.

Thank you!

Ken

I've been there done that not only for me, but for others. I tell folks do research, and spend the money on quality or recommended parts.

These 3v engines are a piece of work all to themselves, it wasn't one of Ford's brightest moves, but it all had to do with fuel economy and staying up with the Jones'.

You said you have ~275K on the engine in a 2004. That's pretty good, considering. I assume you are the only owner. Not sure how you drive, but assuming mixed city/highway (35 mph avg), you've got probably right around 8,000 hours on that engine.

If it's mostly highway (50 mph avg), then you only got 5,500 hours. <--- Inter/Intrastate tractors with some idle included.

At the end of the day, if the truck will last another 200k+, I would rebuild the engine.

It makes me sick. In your estimate, if I just buttoned it up and drove on it what could I expect? That cam tower is the only one with a noticeable ridge to the fingernail. That being said, the cam journal and caps aren't glassy smooth. Getting it rebuilt may be outside the realm for me right now not to mention I just dropped $1,200 on a new timing kit, Melling oil pump and gaskets. I like the truck and everything else in it is good.

Thank you!

Ken

Not sure. Depends on what else happened. You might be lucky and will last another 200k. Without opening it up you'll never know.

Also depends if its your only ride. If you don't depend on it or half depend on it, then eh, I'd just go with fixing it and see what happens.

No one can give you an answer on how long it will last.

I'm fortunate that I don't depend on a single vehicle, as I got a few to choose from, especially this time of the year. If this were to happen to me and I didn't have the money or the time, I'd just park it and wait till I did.

Yeah I fully depend on it. I've got my wife's car but she needs it and I'm a salesman who needs to travel and this is the vehicle I use.

I appreciate all the time you have given to this.

Thank you!

Ken

If the rest of the truck is good and you want to get another 100k out of it, get a Jasper reman engine.

I hear good things and bad things about Jasper. That puts me in another quandary. Are they reliable? I'm looking for anther 250K miles.

Thank you!

Ken

curious too