I noticed a grinding noise coming from the tensioner pulley 1 morning while arriving at work and did not think anything of it until the serpentine belt broke about a block from the house on the way home. I took the tensioner pulley off and noticed that the pulley had grinded into the block causing a crack in the 5.4L block on the passenger side. I do not know if I should go ahead and take the truck to the junk yard or if it is fixable. The crack is done in a circular motion and is aprox 1 1/2 inch in length and 1/8 in width throughout. Any Ideas on how to fix the problem and aprox. amount of cost?

 

What year is the truck (ie, is it still under warranty)? If the block is indeed cracked (you didnt say anything about a leak?) then you are looking at a few thousand to replace the block.

 

HI!... Your block is cast iron, NOT aluminum. All 5.4's have a cast iron block except the 5.4 in the FORD GT. You must mean you have a crack in the front timing chain cover. It's made out of aluminum. If it is easy to get to then have someone weld it up. If not remove the cover and weld it or replace it. You should be able to get a front timing chain cover for a 5.4 from a junkyard for around $100.

Is this what your talking about?

 

Thanx for the reply I went out and looked At the engine again and noticed it was just the timing chain (thank god). I guess a few to many beers and another buddy looking at the crack makes for bad mechanics. Thanks for the good advice on a BS prob.