Ford 5.4 2V Build - Rear Main Seal Replacement

This video is Part 4 of a much longer series of videos that get into a motor project I did with my son. The motor is a 1999 Ford 5.4 Liter 2 valve (2V). When he got the truck it had a bad knocking sound. The oil looked like a silver metallic spray paint when we inspected it so we decided to remove the motor with engine problems and replace it with a used one. It only made sense to replace gaskets and seals as well as do an oil pump replacement with an performance upgrade pump among several other things.

The focus of this video is installing the rear main seal (FelPro part # BS40644) on our 5.4 liter 2 valve motor. I also install a new Ford oil slinger (Ford part # F65Z-6310-A). I understand there are many discussions regarding the oil slinger; some say the oil slinger isn't needed and others believe the oil slinger is critical to ensuring a leak-free rear main seal. Ultimately, my thought was the motor came from the factory with the oil slinger installed so I will install a new oil slinger. The purpose of the videos in this series is just to show you how we did the work so maybe you can save time and learn from the mistakes we made along the way. Do anything you see in the videos at your own risk.

Links to videos in this series (as they become available):
Part 1: Ford 5.4 2V Knocking Sound, Removal, Teardown
   • Ford 5.4 2V Build - Knocking Sound, R...  
Part 2: Ford 5.4 2V Piston & Deck Cleaning - Preparation For Head Installation
   • Ford 5.4 2V Build - Piston & Deck Cle...  
Part 3: Ford 5.4 Liter 2V Block & Parts Painting - Preparation For Assembly
   • Ford 5.4 2V Build - Block, Valve Cove...  

Future videos in this series will focus on the details of individual smaller jobs throughout the project. That should keep them shorter and easier to dive into the detailed how-to's of each project. When possible, I'll provide torque specs, tightening sequences, bolt sizes and helpful tips.

The next video in this series will be installing a new high performance oil pump from Melling. That video will be followed by the threaded CalVan Tools spark plug inserts. Other videos in this series will include prepping the heads, head gasket replacement, timing chain kit, and more!

As an Amazon Affiliate I earn from qualifying purchases.
Links to products used:
Fel Pro Rear Main Seal - https://amzn.to/3LfAtRz
Ford Oil Slinger - https://amzn.to/3T4TFUf
Permatex Ultra Black Gasket Maker - https://amzn.to/3J0zwdi
3M Roloc 2 inch disc 120gr - https://amzn.to/3ZGnj3Y
2 Inch disc holder - https://amzn.to/3kI83oF
3M Scotch-Brite pads - https://amzn.to/3IRpTxm
Lisle 52000 Razor Blade Scraper - https://amzn.to/3kLx02w
Plastic Razor Blades - https://amzn.to/3KVxNbY
3M Particulate Respirator - https://amzn.to/3Zbcbwl
Milwaukee Cordless Drill Kit - https://amzn.to/3SQExd4
Hopkins Drip Tray - https://amzn.to/3y8pHoL

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DISCLAIMER: The information provided in this video is for educational and entertainment purposes only and should not be construed as professional advice. The creators, producers, and distributors of this video do not assume any responsibility or liability for any errors or omissions in the content of this video or for any damages arising from the use or reliance on the information presented in this video. Viewers should consult their own professional advisors for advice and guidance. The use of any information provided in this video is solely at the viewer's own risk.