I'm going to start building a 4.0 block to 4.6 for my 2004.
Having never built an engine before, i'm excited to start. I have plenty of good help and support around me, just need some guidance on where to start pricing parts.
I want to build it right...
I believe I need the following components.
-New Rear Main Seals
-New Rod Bearing
-Crankshaft bearings
-Crankshaft
-Camshaft bearings
-Camshaft
-Lifters
-ARP Studs

Looking for suggestions on where to start pricing... I'm just unsure of my options for the different components.

Thanks... Looking forward to the replies.

 

Check out British v8 v Buick stroker.. lots of good info and a bad *** Rover motor. also cannibal v8 had good info and parts

 

Since the 4.0 blocks had the thinner walls between cylinders aren't you asking for trouble?

Why not find a 4.6 block to rebuild?

 

You would be far better off with rebuilding a 4.6 than a 4.0 to a 4.6
What is wrong with your current 4.6 block?

 

What do you mean they had thinner walls?

 

Where are you coming by this info? I don't think I've ever heard of the 4.0l blocks being any thinner than the 4.6l...at least not the 4.6l blocks used in the D2s.

I do know that I've heard tales of voids in the D2 4.6l blocks from some of them being mis-cast toward the end of that engine block's production run.

 

Pistons are different from 4.0 to 4.6. If you use 4.0 pistons, your compression ratio will go up. Are you just going to use the guts from your 4.6? If so, then all you need is bearings, seals/gaskets, and rings. (of course I'm probably forgetting something.)

 

That information is not accurate. The best 40 or 4.6 blocks came from a 98 to 99 D1 and P-38 which were made from a better aluminum.
The newer 4.6 tend to over heat compared to a 4.0.
Also to convert a 4.0 to a 4.6 you also need new pistons and rings and if you were going to all that trouble, you would want to change out the sleeves to t-hat's to prevent sleeve movement.

 

The blocks are identical. The only difference is the quality control.

 

Anything to back up this statement?