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My 4.9L build

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MechRick
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Posts: 877
Joined: Wed Jan 04, 2012 7:43 pm
Location: Las Vegas, NV

My 4.9L build

Post #1 by MechRick » Mon May 04, 2015 10:42 pm

I found these hiding in a directory in my hard drive and I thought I would share them. It's the build of the engine that's currently in my blue F150. It is a mild upgrade from stock, and runs well, so here you go.

I built this engine in 2009-10 for my '86 Bronco. It got an Offy DP with a Holley 390 4bbl and a Comp 268H cam.

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I took the block to work to clean, and had concerns it would not fit in the trunk of my notch Mustang....

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...but there it is. Anyone who has owned one of these knows the trunk is *small*.

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Back from cleaning, first step is to drill out the fuel pump pad for the lever...

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Hole is just big enough to clear the pump arm.

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I got lucky on this Craigslist engine. It's out of a '96 F250 with 118,000 miles, and the factory crosshatch is still visible in the bores.

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I haven't touched the bores at all. Just cleaned the block, done.

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Comp 268H. I found out the hard way that this cam is too big for towing, at least at the EFI compression level. I couldn't keep it from pinging until I put a stock spec Melling in.

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Cheap aluminum cam gear.

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Checking the cam setup. It ended up .5 degrees advanced. Close enough.

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Dial indicator to check lifter rise.
1994 F150, 4.9L/ZF 5 speed, C-Vic police driveshaft
EFI head w/mild port work, 3 angle valve job
1996 long block, stock pistons, ARP rod bolts
Stock cam, aluminum cam gear
Hedman header, full mandrel bent duals, crossover, super turbos
http://fordsix.com/forum/viewtopic.php?f=2&t=73244
Bronco II with a 2.3L swap http://fordsix.com/forum/viewtopic.php?f=13&t=72863
1988 F250 2x4, 460 ZF 5 speed.

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MechRick
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Posts: 877
Joined: Wed Jan 04, 2012 7:43 pm
Location: Las Vegas, NV

Re: My 4.9L build

Post #2 by MechRick » Mon May 04, 2015 10:43 pm

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Indexing off the edge of the lifter.

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Checking the piston dish volume.

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Streamlined the valve guide bosses and got rid of the sharp edges in the bowls. Stock valves, although they did get 3 angle seats.

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Checking for straightness.

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My 60 year-old Sioux machine at work. This one started it's career at a CHP garage in Los Angeles.

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Assembled head.

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Pistons going in. Stock rings, believe it or not. I removed them, scraped all of the carbon from the stock pistons, reassembled them and put them back where they were.

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I did spring for ARP wavelocks though. Chalk that one up to 17 years as a Ford tech. Almost all of the bottom end problems were failed rod bolts.
1994 F150, 4.9L/ZF 5 speed, C-Vic police driveshaft
EFI head w/mild port work, 3 angle valve job
1996 long block, stock pistons, ARP rod bolts
Stock cam, aluminum cam gear
Hedman header, full mandrel bent duals, crossover, super turbos
http://fordsix.com/forum/viewtopic.php?f=2&t=73244
Bronco II with a 2.3L swap http://fordsix.com/forum/viewtopic.php?f=13&t=72863
1988 F250 2x4, 460 ZF 5 speed.

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MechRick
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Posts: 877
Joined: Wed Jan 04, 2012 7:43 pm
Location: Las Vegas, NV

Re: My 4.9L build

Post #3 by MechRick » Mon May 04, 2015 10:44 pm

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I wish I had a better shot of the hypers Ford used in the '95-'96 engines. They are classy slugs.

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Head on, checking lifter clearance. The 4.9L has plenty of hydraulic lifter cup motion, over .100". I had about .040" pointer movement before the pedestal bolt got tight.

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A little gloss black...

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Mounted in the Bronco.

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And, during my brief stint in the PNW. A tree fell on it during an ice storm. Oh well, I wanted a pickup for it's better towing capability anyway.

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Bought this and swapped the fresh 4.9L and ZF in.

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The '94 is EFI, so I swapped it over. The '96 upper has been redesigned, and I still had the original so I used it. Knowing I would have to swap back to a stock cam, I added the header. Notice the starter. You have to put it there or it will not go in later...

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Engine is on the left. I put mandrel exhaust on this one, with a short crossover tube after the rear collector.

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Quiet Super Turbo mufflers.

Of the 3 300/4.9L's I've owned, this one runs the best. Aside from the port work, the straight-up cam timing and the header/exhaust, it's essentially stock.
1994 F150, 4.9L/ZF 5 speed, C-Vic police driveshaft
EFI head w/mild port work, 3 angle valve job
1996 long block, stock pistons, ARP rod bolts
Stock cam, aluminum cam gear
Hedman header, full mandrel bent duals, crossover, super turbos
http://fordsix.com/forum/viewtopic.php?f=2&t=73244
Bronco II with a 2.3L swap http://fordsix.com/forum/viewtopic.php?f=13&t=72863
1988 F250 2x4, 460 ZF 5 speed.

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THE FRENCHTOWN FLYER
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Location: FRENCHTOWN

Re: My 4.9L build

Post #4 by THE FRENCHTOWN FLYER » Tue May 05, 2015 11:19 am

Nice post - thanks for sharing.

Sorry about your Bronc. But the truck looks spiffy.

I have a similar Sioux valve grinder and I love it. I think it is better than a QuickWay.
FORD 300 INLINE SIX - THE BEST KEPT SECRET IN DRAG RACING

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tom954x4
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Joined: Sun Nov 22, 2009 4:32 pm
Location: Twilight zone, WA

Re: My 4.9L build

Post #5 by tom954x4 » Wed May 06, 2015 12:47 pm

nice photos Mech Rick!
Did all the 1995 300s have the hyper pistons? I've seen others say the 1996s had them, but am not sure about the '95s - like the engine in my truck.
1995 F-150 XL, 300-6, 4x4, ex-cab, sb, 3.08 5-speed, 2 1/2 in. exhaust w/flowmaster 50, MSDignition failed with no warning, now out, canopy, 179,000 + miles. Gone but not forgotten 1965 F-100 240 3spd lwb "the green hornet"; 1960 F-250 4x4, 223 six, 4sp with wrap-around rear window, two-tone paint, overhead camper.
Tow vehicle: 2012 F-250 4x4 6.7 diesel XLT s/c lwb

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MechRick
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Location: Las Vegas, NV

Re: My 4.9L build

Post #6 by MechRick » Wed May 06, 2015 1:01 pm

I'm not sure. We need input from someone who has had a '95 apart. Unfortunately I haven't.

There were quite a few changes on the '95-'96 engines though.
1994 F150, 4.9L/ZF 5 speed, C-Vic police driveshaft
EFI head w/mild port work, 3 angle valve job
1996 long block, stock pistons, ARP rod bolts
Stock cam, aluminum cam gear
Hedman header, full mandrel bent duals, crossover, super turbos
http://fordsix.com/forum/viewtopic.php?f=2&t=73244
Bronco II with a 2.3L swap http://fordsix.com/forum/viewtopic.php?f=13&t=72863
1988 F250 2x4, 460 ZF 5 speed.

deere114
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Posts: 367
Joined: Thu Sep 19, 2013 7:57 pm

Re: My 4.9L build

Post #7 by deere114 » Wed Jun 24, 2015 11:58 am

Did you happen to note the piston dish volume? I have a 96 short block I want to freshen up with a carb head and want to figure compression ratio. Also how far below deck were they with no block decking if you remember? Of like to figure quench distance for my build as well.

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MechRick
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Joined: Wed Jan 04, 2012 7:43 pm
Location: Las Vegas, NV

Re: My 4.9L build

Post #8 by MechRick » Wed Jun 24, 2015 4:57 pm

I did. Had to to figure out the static compression ratio, which I know that I did. I'll check my notes. I remember that it was a tenth of a point lower than the factory rated compression ratio. Ford combustion chambers specs are usually the minimum. In other words, if it calls for a 76cc chamber, it will be 76cc or bigger.

The pistons were very close to zero deck, AFAIK.
1994 F150, 4.9L/ZF 5 speed, C-Vic police driveshaft
EFI head w/mild port work, 3 angle valve job
1996 long block, stock pistons, ARP rod bolts
Stock cam, aluminum cam gear
Hedman header, full mandrel bent duals, crossover, super turbos
http://fordsix.com/forum/viewtopic.php?f=2&t=73244
Bronco II with a 2.3L swap http://fordsix.com/forum/viewtopic.php?f=13&t=72863
1988 F250 2x4, 460 ZF 5 speed.

motzingg
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Joined: Tue Apr 30, 2013 8:16 am

Re: My 4.9L build

Post #9 by motzingg » Wed Jul 08, 2015 4:52 pm

I've seen your other posts about this engine and the knocking with the carb/268H setup when towing. I wonder if that is due to the EFI heads? I guess i never put 2+2 together to realize you were seeing that problem on the 268 with an EFI head using a carb.

what is the logic behind the resonator/second muffler on only one pipe?

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MechRick
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Joined: Wed Jan 04, 2012 7:43 pm
Location: Las Vegas, NV

Re: My 4.9L build

Post #10 by MechRick » Wed Jul 08, 2015 4:56 pm

It's hard to tell from the picture, but it's just duals with a crossover. The mufflers are staggered because the header outlets are...
1994 F150, 4.9L/ZF 5 speed, C-Vic police driveshaft
EFI head w/mild port work, 3 angle valve job
1996 long block, stock pistons, ARP rod bolts
Stock cam, aluminum cam gear
Hedman header, full mandrel bent duals, crossover, super turbos
http://fordsix.com/forum/viewtopic.php?f=2&t=73244
Bronco II with a 2.3L swap http://fordsix.com/forum/viewtopic.php?f=13&t=72863
1988 F250 2x4, 460 ZF 5 speed.

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