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My 4.9L build

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MechRick
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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.

Image

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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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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Location: Las Vegas, NV

Re: My 4.9L build

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

Image

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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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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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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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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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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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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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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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.

sdiesel
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Location: NW Oregon,Buxton currently

Re: My 4.9L build

Post #11 by sdiesel » Thu Nov 14, 2019 12:51 am

what is the status of this engine?
one of my favorite threads. teaches a bunch in a few pics
a long love affair with the 300 six.
my lastest and final fling is a fresh 300 in an 88 ford f350 dually 4X flatbed

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MechRick
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Re: My 4.9L build

Post #12 by MechRick » Thu Nov 14, 2019 5:33 pm

Sold the truck a few months ago. Still see it running around town.

I needed a truck with a bit more tow capacity. Ended up with an '88 460/ZF5 F250.
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.

sdiesel
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Location: NW Oregon,Buxton currently

Re: My 4.9L build

Post #13 by sdiesel » Fri Nov 15, 2019 12:17 am

interesting.
the 88 460 is a pathetic engine with tons of potential.
my 88 tonner dually, had the 460, C6, and now a 300 zf 5.

my 300 has more power, better economy, less weight, and runs a lot cooler....
but I still wonder if I should have given up that 460....
that may be the best big block ever made, with the 440 a very close 2nd.
or perhaps first among equals.

so did u need greater power to tow?
heavier axle?
a long love affair with the 300 six.
my lastest and final fling is a fresh 300 in an 88 ford f350 dually 4X flatbed

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MechRick
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Re: My 4.9L build

Post #14 by MechRick » Fri Nov 15, 2019 2:35 pm

I bought it for the 8 lug axles and low miles (114,000). The heavier truck deals with the Greyhound-bus-passing-the-bumper-tow-travel-trailer-white-knuckle-experience better than the half ton chassis.

sdiesel wrote:the 88 460 is a pathetic engine...


Hey, I resemble that remark! :D

Alas, you are correct. '88 was the first year for EFI in the big blocks. Rated 235 HP, 365 torque. Those *might* be the worst 460 numbers published.

I toyed with the idea of quench pistons and some head work, but an IDI would be the smart swap. It supposedly will bolt to the big block ZF after some careful drilling.

A turbo 4.9L would work well too.
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.

pmuller9
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Location: Columbus, Indiana

Re: My 4.9L build

Post #15 by pmuller9 » Fri Nov 15, 2019 5:36 pm

Turbocharged 460?

sdiesel
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Re: My 4.9L build

Post #16 by sdiesel » Fri Nov 15, 2019 6:25 pm

currently there are 3 IDI'S here in this stable.
they multiply when not carefully tended.
it seems no one wants them.
indeed the IDI makes me yearn for the smooth power of a big gas.
but, my ears love the idea of hearing how u might go about assembling a 300.
I'm guessing sequentially, with MS, edis etc.
would be something, for sure.
a long love affair with the 300 six.
my lastest and final fling is a fresh 300 in an 88 ford f350 dually 4X flatbed

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MechRick
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Re: My 4.9L build

Post #17 by MechRick » Fri Nov 15, 2019 8:30 pm

pmuller9 wrote:Turbocharged 460?


I've already done the math. Something around a 96 mm with exhaust AR around 1.3 would net 1000 ft-lbs and 800 HP. :hmmm:

It would probably get better fuel economy too.

sdiesel wrote:my ears love the idea of hearing how u might go about assembling a 300.
I'm guessing sequentially, with MS, edis etc.


I think sequential is overrated and overly complex for a pickup. I have no bias against distributors, but COP would make more room for plumbing.

As FTF has alluded, getting the header right (and reliable) would be the challenging part...
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.

pmuller9
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Location: Columbus, Indiana

Re: My 4.9L build

Post #18 by pmuller9 » Fri Nov 15, 2019 10:41 pm

sdiesel wrote:love the idea of hearing how u might go about assembling a 300.
I'm guessing sequentially, with MS, edis etc.

First part of the project would be fabricating stainless steel headers using FTF's specs where the exhaust flange covers the entire portside of the head using all of the bolt holes in the head for support.
Custom intake would bolt on top of the exhaust flange.

Holley HP EFI and coil near plug ignition.
If the engine is going to see a lot of low rpm cruising then I would use Sequential Injection for possible gas mileage gains.
At low rpm and short injector pulse widths, if the injector is timed to inject just after the exhaust valve closes during the intake cycle there is little chance for raw fuel to go out the exhaust.

sdiesel
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Re: My 4.9L build

Post #19 by sdiesel » Sat Nov 16, 2019 12:09 am

MechRick wrote:
pmuller9 wrote:Turbocharged 460?


I've already done the math. Something around a 96 mm with exhaust AR around 1.3 would net 1000 ft-lbs and 800 HP. :hmmm:


this is terrifying.

a while back sick 6 did his 300 turbo thing, was real cool.
he later turbo ed a 460 in a plow truck with interesting result. truck was late 80's f250 rust bucket, you tube videos show scary accel.

a note on the zf swap.
please check gear ratios on the 5 speeds, I do recall they may be different for each engine.
if so, I have guts of a diesel zf I can drop off this winter on my route to San diego.
a long love affair with the 300 six.
my lastest and final fling is a fresh 300 in an 88 ford f350 dually 4X flatbed

pmuller9
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Re: My 4.9L build

Post #20 by pmuller9 » Sun Nov 17, 2019 8:08 pm

sdiesel wrote:he (Sick6) later turbo ed a 460 in a plow truck with interesting result. truck was late 80's f250 rust bucket, you tube videos show scary accel.

I just love the turbocharger mounted in the truck bed under the tool box.

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Re: My 4.9L build

Post #21 by bubba22349 » Sun Nov 17, 2019 8:38 pm

:shock: we're is the link for it? :nod:
A bad day Drag Racing is still better than a good day at work!

My Ex-Fleet of Sixes sadly these are all long gone! :bang: 1954 Customline 223 3 speed with O/D, 1963 Fairlane project drag car with BB6, 1977 Maverick 250 with C4, 1994 F-150 a 300 with 5 speed.

pmuller9
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Location: Columbus, Indiana

Re: My 4.9L build

Post #22 by pmuller9 » Sun Nov 17, 2019 9:15 pm

bubba22349 wrote:we're is the link for it? :nod:

Sick comes up with some really great "out of the box" thinking
https://www.ford-trucks.com/forums/1477 ... st17133688

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Re: My 4.9L build

Post #23 by bubba22349 » Sun Nov 17, 2019 11:25 pm

:beer: That's very interesting wonder how effeciant that is, it could be quite a stealth system too. Thank you Paul! I really liked his 300 six build too. :thumbup: :nod:
A bad day Drag Racing is still better than a good day at work!

My Ex-Fleet of Sixes sadly these are all long gone! :bang: 1954 Customline 223 3 speed with O/D, 1963 Fairlane project drag car with BB6, 1977 Maverick 250 with C4, 1994 F-150 a 300 with 5 speed.

sdiesel
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Re: My 4.9L build

Post #24 by sdiesel » Mon Nov 18, 2019 12:13 am

He one of my favorite builders:

He runs risks, but has the savvy to get himself outta trouble, if he blows something up.
....builds beautiful, radical stuff.

remote turbos are sexy.
long tube headers , ceramic coating, wrapped
twin scroll turbo
shorty exhaust post turbo
no intercooler
and of course propane fuel,
no excessive engine bay heat.

i can't remember with certainty but i believe that little pickup was using a cheapie turbo, just stuff he had laying around, stitched it together and BAM!
I want one.
a long love affair with the 300 six.
my lastest and final fling is a fresh 300 in an 88 ford f350 dually 4X flatbed

65 F-100 pete
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Re: My 4.9L build

Post #25 by 65 F-100 pete » Tue Dec 31, 2019 6:27 pm

Hello MechRick, I am looking to do to my 240 ci, what you did to your engine. A mild build. What ignition are you using? What was the cost of what you did please ?
I have had my '65 F-100 for going on 39 yrs. 6 months ago, I put dual cast iron headers on. Same 1 bbl carb. I have two mufflers like you. What an incredible difference in performance ! I like the idea of a 4 bbl. Use the smaller two for in town...then use all four to really, "giddy up".
look forward to hearing from you.
Happy New Year, Pete

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MechRick
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Re: My 4.9L build

Post #26 by MechRick » Thu Jan 02, 2020 12:13 pm

Hi Pete.

In the beginning, I set up the engine for use in a carbed Bronco. I used duraspark distributor and module. If you switch to an Offy intake, be careful there is no interference between the exhaust manifolds and intake. I didn't, and broke one of the ears on the intake and had to have it tig welded back on. The Offy with a correctly tuned 4 bbl will get very near the same MPG as the 1 bbl.

My preference is mechanical fuel pumps. The cheapo electric ones have sketchy reliability, not something I wanted in a 4x4 that goes 50-100 miles away from paved roads.

As far as cost, because of the excellent information in this forum I went looking for a '95-'96 4.9L to get the better pistons. I think I paid ~$350 for the 119k used engine, a Craigslist find from a guy that was swapping a 5.0L in his F250. I didn't have the heart to tell him he was going backward.

Above that, it was just crank/rod bearings, rod bolts, paint, cam and lifters, timing gears and good rubber seals for the engine. Maybe $350 and 30-40 hours of my time. I got lucky and only had to resize one connecting rod. In my post above, I stated they were ARP wavelocks. They weren't. Just standard ARP hardware.

When swapping into the '94 with injection I switched out the duraspark for a TFI-IV with a hall effect, controlled by a Megasquirt 1.

I highly recommend the method above to get the most bang for the buck. I lucked out as far as cylinder wear. A simple cranking compression test would have been prudent before purchase. But finding a good used 96-ish long block to start with is the way to go.

The ZF 5 speed was another C/L find. The '86 Bronco had a 9 inch rear diff from the factory, with the 44 TTB in the front. Traclok in the rear. This represents one of the best factory part combinations for a capable and reliable 4x4 with a good crawl ratio, loads better than my current Bronco II. Mileage isn't too far off either (16-ish vs 21-ish).

I don't know the quality of the stock cast 240 pistons. Someone who has experience with them should chime in.
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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