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Unread 08-22-2011, 10:25 PM   #1
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What should a 4.0 rebuild cost?

Developed a small knock and figured with all the money I have invested in this thing to have the motor pulled and rebuilt. Very minor knock but a knock nonetheless. Assuming pistons and everything else checks out what should it cost? Also, If anyones near Chicago that can do this or knows someone let me know.

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Unread 08-23-2011, 07:59 AM   #2
XJ on 37's
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1998 XJ Cherokee 
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Location: missouri via blackpool,lancs.
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And there is the issue.
You mention full rebuild, then say "assuming pistons and everything else checks out".
I have been saying for quite a while now that one persons version of a rebuild is not the same as another persons version of a rebuild.
I will not rebuild a motor with the same pistons in it.
ALL my motors get the crank ground, bored out with new pistons and rings, all new bearings, deck the block, pressure test and skim the head(s), new oil and water pumps, new camshaft and lifters, line bored for the main bearings, and so on.
That comes to @$800-900 in machine work alone, and you haven't bought any parts yet.
Rebuild "kits" can be had for reasonable money with name brand parts inside in most cases.
You could always buy a "remanufactured" motor and keep your fingers crossed. 99% of those places will only replace something if it is completely shot though.
Doing it yourself/having it done for you, is the way to go for a rig that you plan on keeping a long time. That way you can spec out the build from start to finish.

1998 XJ on 37's.JK Rubi axles with chromo shafts and ctm's, 4:1 transfer case, etc etc etc.The Cherylkee....
2003 Range Rover HSE, 4.4 Quad Cam.
1998 Range Rover 4.6 HSE
2000 4.7 4WD WJ with a rebuilt motor.
4.3/700r4/new frame buildup (YJ)....

Years to gain the hands on experience, and offer it freely.
Minutes to gain the knowledge from the internet, and quote it just as freely.
Choose wisely!
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Unread 08-23-2011, 08:58 AM   #3
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I bought a crate motor for my XJ from the dealer. I dickered with him and I got him down to $1,100 for a long block. You can't do a GOOD re-build for that price, plus it came with a 3 year 36,000 mile warranty.
14 KL
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Unread 08-23-2011, 10:47 AM   #4
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1996 XJ Cherokee 
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a good rebuild should be at least 1300 if you're expecting any quality. i found a shop that would rebuild mine for 1000 but i found a review online that said they started getting engine problems 30K after the rebuild.

96 XJ, geared, 8.8, 5", 33s, dash
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Unread 08-23-2011, 02:37 PM   #5
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You could look for a low mileage junkyard engine, that should run around $500.
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Unread 08-23-2011, 03:51 PM   #6
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I just rebuilt my 4.0, after machine work, master rebuild kit, and additional parts, water pump, alternator etc, I just spent about 1800. Its worth it to me, I did the 4.8L stroker rebuild, a brand new spankin engine with more power? whats not to love.
92 XJ

My XJ Build
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Unread 08-23-2011, 05:22 PM   #7
It's the crank sensor!
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1999 XJ Cherokee 
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$1300 - $2000 depending on a lot of variables. Be sure you get at least 2, better to get 3 quotes before making any decision.

And as mentioned, consider a plug and play salvage yard engine. To each their own on these decisions.

A very minor knock may not necessitate a rebuild. The knock could be a bit of piston slap or valve noise; neither of these uncommon with the 4.0

What I recommend for these is to DRIVE IT, and keep an ear to it. If the noise gets no worse, keep driving it. I have seen many, many 4.0 engines run for tens of thousands of miles with a bit of a knock.
99 Cherokee, 4.0 AW4, NP242
Past Jeeps: 49 Willys, 81 Scrambler, 88 Comanche
Without "data", all you have is an opinion!
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Unread 08-23-2011, 05:47 PM   #8
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Just had mine rebuilt locally. Took it to a shop that I knew was meticulous and used quality parts. $ 2000.00 out the door. Runs like a top - well worth it. However I had done about everything else (trany, clutch, rear end etc...) already so it made sense to do the engine.
I'm right 97% of the time. The other 4% doesn't matter.
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Unread 08-23-2011, 06:40 PM   #9
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If you pull the engine yourself ballpark around $1000-1300. For a turn key $1800-2000
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