I know the Boss engine is advertised as all aluminum, but what is used for cylinder lining? Is it the sames as the 5.4 Shelby GT 500 plasma spray, cast iron sleeves, or something else?

Bill

 

This 5.0 Mustang magazine article has extensive detail about the engine in your car. This one has a ton about the 5.0L Coyote on which it is based. The cylinder liner is pressed-in iron.

 

Tony,Thank you for the link " a great read "

 

Tony,
Thanks for the links. Good articles.
Those iron sleeves are pretty thin. Doesn't look like they can ever be machined.

Bill

 

remember usually a rebore unless there is extreme wear is 30 thousands of an inch. .030........so half of that is 15 thousands........pretty sure judging from the thickness of the steel compared to the cylinder head bolt hole it could probably go .060 over.........and im sure its a metric size too......i used to own my own automotive repair and machine shop........If it gets too bad then you bore the cylinder out as close as you can to the aluminum, chip out the reminder and then press in a new sleeve, then bore back to standard.

 

On modular V8's if I have had bored out I go .020 over. You can go .030 but thats the limit. I have not built one using the new 5.0 block but I am willing to bet .020 probably is the safe limit on the block.

 

These liners are very thin. They start out around 2.5mm wall thickness and end up around 1.5mm wall thickness after finish machining.

They heat the block prior to pressing the liners in.

I haven't heard what you really need left of the liner after a rebore. 1.5mm doesn't leave much room. A .030"(.762mm) overbore will only leave a little over 1.0mm wall left. Is that enough?

In some engine designs they freeze the liners prior to pressing them in. (GM's L-850 In-Line is done this way.)

When the parent bore in the block is too small (undersize limit) and the liner is near max. dia. tolerance the liners can explode like an egg shell during the press operation.