When you depend on fierce reliability from your truck every day, the one thing you don’t need is engine and driveline failure at an inopportune moment. What’s more, you don’t want a lot of downtime waiting for a local overhaul shop to rebuild these critical components and get them back in your truck. You’d probably like a warranty, too.
Replacing your engine and transmission with a Jasper stock replacement will cost considerably less than replacing your vehicle. Think about it. Look at the economics of a new vehicle: payments, licensing, and insurance. You also likely have a feeling of comfort with your truck because you’ve become accustomed to its nuances and know its maintenance history. What’s more, just remember why you bought it in the first place.
Jasper stock replacement crate engines (for most applications) are available from a nationwide inventory located in its distribution network across the United States. This means your truck can be back up and running again in the time it takes to have someone else go through the process of tearing down and rebuilding your engine locally.
| We’re working with an expired Ford 4.0L SOHC V-6, which is common in Ranger and Explorer trucks and some Mustang automobiles. This one managed to swallow a valve after more than 200,000 miles of operation. We’re going to show you how to get into a remanufactured engine and transmission from Jasper.
Most Jasper remanufactured engines and transmissions are covered by a 3-year/100,000-mile (whichever occurs first) nationwide warranty. Ambulance, off-highway use, package delivery, police, snow removal, taxi, tow truck, transit bus, or any vehicle weighing more than 1 ton receives a warranty of 18 months or 100,000 miles, whichever occurs first. Is any engine or transmission builder in your community willing to send you on your way with a warranty like this?
This article focuses on a 4.0L SOHC V-6 ’01 Ford Ranger pickup that suffered the indigestion of a swallowed valve. The owner, who counts on this vehicle for the morning commute, explored his options and contacted a number of machine shops and rebuilders. It was when he contacted Jasper Engines & Transmissions that he found the most suitable solution for his needs. After more than 200,000 miles of tough Southern California freeway mileage, he decided it made great economic sense to replace the Ford V-6 along with its 5R55 automatic overdrive transmission—both available from Jasper.
Advanced planning and lots of photo documenting are key to a successful crate engine swap. You need to have all the support parts ordered prior to pulling your engine and transmission. This means sensors, hoses, and other key parts in your hands before you even get started. You also have the option of working with a Jasper-authorized dealer, which can perform the engine and transmission swap.
| Begin your engine swap with a thorough cleaning with an engine degreaser like Simple Green or the like. A clean engine bay makes disassembly and removal easier. Wear latex gloves to protect your skin and eye protection. Did you remember to disconnect the battery?
Why Engines Fail
Engines fail due to wear, tear, and neglect. They also fail due to electronic engine control issues that create their own amount of engine anxiety. If you’ve had a “Check Engine” light for any length of time and ignored it, this element alone would cause a certain amount of engine damage. Electronic engine control relies on the sum total of its sensors and various forms of feedback to keep your engine well fed and tuned. A “Check Engine” light, depending on the manufacturer, typically means there is an electronic engine control system in open loop or “limp home” mode, where fuel mixture and spark timing are not optimum. Operating this way over a lengthy period of time takes a toll on an engine.
Your crate engine agenda should include all the elements of electronic engine control— oxygen (O2) sensors, throttle position sensor (TPS), inlet charge temperature sensor, mass air sensor, coolant temperature sensor and sender, EGR and evaporative emissions sensors, EGR valve, and cylinder head temperature sensor. Some of these items, such as the O2 sensors, cost plenty—so does engine failure if you don’t replace them. Catalytic converters are another replacement item, especially if your truck has more than 200,000 miles showing. These items get your replacement engine off to a good start.
And finally, before you fire the engine, make sure you’ve covered all the bases, including getting fresh oil in the pan, fluid in the transmission, and coolant in the radiator. You would be surprised how many of us miss this one—engine/transmission survival fluids —and wind up with an engine and driveline just as trashed as what we replaced. Double-check your work and make sure your Jasper engine is ready to fire.
| Engine and transmission removal begin with the systematic removal of parts and photo documentation of this process. Images give you a reference for how things came apart and how they go back together. Parts should be carefully marked and stored. Keep disposable plastic containers for parts and mark them accordingly.
| Store and document all parts as disassembly ensues. Never trust your memory. Photograph, document, and carefully store. Take note of what needs to be replaced and order it now.
| Most of today’s trucks have a common multiplex plug that completely disconnects the engine electrically. There are typically two fuel lines—pressure and return—that must be disconnected. The cooling system should be drained and coolant properly disposed. While you’re underneath the truck, drain engine oil and transmission fluid.
| With most of today’s trucks, you’re going to have to remove the intake manifold and related components to gain access to take out the engine. Keep track of all fasteners and put them in a marked container. Ford’s SOHC V-6 intake manifold calls for Torx fasteners. Front accessory dress must be removed, including the cooling fan, power steering pump, and radiator. Protect the air-conditioning compressor with a plywood board. Do everything possible to avoid disconnecting air-conditioning lines.
| Special care must be given to connectors, which have become brittle over time due to heat and ozone. They’re expensive to replace, which calls for extreme caution.
| With all engine and transmission connections handled and fluids drained, we’re ready to pull the engine.
| This is the way Jasper delivers its remanufactured engines and transmissions to your door. Jasper arrived at our door with a lift truck downloading this crate and hauling it into our garage with a pallet jack.
| Our Jasper remanufactured Ford 4.0L SOHC V-6 has been SIM tested, which involves an oil pressure check and listening for noise before shipment.
| Crate Engine Transmission Jasper Ford V6
| We decided to order a remanufactured 5R55 automatic overdrive from Jasper while we were performing long-overdue maintenance on the Ranger. Like the engine, it arrives on your doorstep ready for installation with a warranty.
| Jasper provides engine and transmission crating. All you have to do is crate the old engine and transmission in these provided crates and call for pickup. Don’t forget to transfer parts from the expired engine and transmission. Check every detail.
| Jasper offers nice options like this engine installation kit, which costs extra but is well worth it in time saved.
| Crate Engine Transmission Jasper Gaskets
| Items like the harmonic damper have to be transferred to the Jasper reman. Here, we’re removing the old engine’s damper for installation on the Jasper engine. The front crankshaft seal must be lubricated with engine oil or assembly lube and the damper carefully installed following the manufacturer’s specifications.
| The flywheel or flexplate has to be transferred to the Jasper engine. Bolts get a dressing of thread locker and are torqued to specifications in crisscross fashion. The block plate has already been installed.
| Pesky little items like valve covers have to be removed from the old engine, cleaned up, and fitted with new gaskets provided in the engine installation kit.
| Crate Engine Transmission Jasper Internal Items
| Items we don’t often think of, like exhaust manifolds, are not included with the Jasper engine. They have to be transferred to the Jasper reman. Jasper has included the exhaust manifold gaskets in the engine installation kit.
| If you’ve had idle quality issues, look to engine electronics like this idle air control (IAC) solenoid. These guys get coked up and stick, which affects idle quality.
| This is the exhaust gas recirculation (EGR) valve, which should be replaced.
| The water temperature sender and sensor are located in this coolant manifold, which is bolted to the intake manifold on the Ford SOHC V-6. They must be replaced.
| Fuel injectors are a hot button item in any engine replacement. RC Fuel Injection can take your existing fuel injectors, clean them, flow-check them, and return them to you for a fraction of what new fuel injectors cost. Fuel injectors rarely wear out. Have them cleaned and checked. It’s that easy.
| The engine and transmission are mated as shown. As long as you don’t disturb the torque converter, which has been installed by Jasper, uniting the engine and transmission should be easy.
| Crate Engine Transmission Jasper
| We’re able to install both the engine and transmission by using an adjustable engine sling, which allows you to tip the engine and transmission so both will clear the radiator support. Your Jasper engine should come with a new radiator and other key support items. Break your Jasper engine in with the manufacturer’s recommended SAE-spec engine oil. Once break-in is complete in 1,000 miles, switch to a good synthetic oil and high-grade oil filter.
| The reason you purchase a remanufactured engine/transmission is the close attention to detail in the remanufacturing process, along with a strong warranty to back the product. Jasper has OEM-caliber production standards, hence the warranty.