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Do repeat valve problems mean I'm pushing my 6cyl engine too hard!?

MomoJeep

Basic User
City
Seattle
State
WA
Hey guys,

I'm wondering if I push my engine too hard and/or are under-powered? Or if I'm just having some bad luck. I really don't want to be messing around with engine problems. I want something that works reliably. Here's what I'm running and here's what's happened:

Original 258 rebuilt block (bored over). Mild RV cam. 4.0L head conversion with Mopar MPI. This head conversion includes some blocked off water jacket passages in the head that don't exist on the block.
3.31 gears, AX-15 5sp w/overdrive, D300. 32" tires. Hard top and rook rack and typically carrying gear/people. Some long roadtrips, some desert heat (Utah), and then sitting for a a year or two in the wet PWN climate (before the most recent failure).

First failure: A long time ago, shortly after the rebuild, some kind of valve issue. The rebuilder used Stainless Steel valves. Something bent I think. So I brought it back and he put in regular
valves.

Second failure: The valves started tapping hard after a long Western US roadtrip with three people and lots of gear (roof rack included). Jeep is loaded down heavy. Mountain passes and hot deserts in summer. Turns out the valve seats were hammered down into the head and the head itself was damaged and not salvageable.

Third (current) failure: After the previous failure, I found a place in Florida selling used heads reconditioned for the exact conversion. The water jackets came already plugged. I had a professional shop do the work. There was some issue in the previous head of measuring and getting custom pushrod lengths, which I did DIY. This time around, the shop made them all the same standard length and believe compensated by machining the posts / mount surfaces. So I have ran this version now for a few years. It was running strong right after this new head was put on. Then it sat out in the wet PNW climate for a year or two with me just firing up the engine for 20 minutes every now and then. Then I started drving it again. Did a long roadtrip from WA state to UTAH last spring/summer. No problem. Did another one this fall and saw the gas mileage dropping and engine idling rough. Check fuel, spark, compression and air, all good. Replaced old (dead) Oxygen sensor, but still running rough. Took to the shop, they are saying I have a bad exhaust valve on Cyl #2. It's dropped down in the valve seat and is sticking. Sound like we can pull the head and re-do the seats, and re-use it. BUT...

Why is this happening? Should I not be driving (up tp) 70+mph on long roadtrips with my jeep loaded down with this engine? Have I overloaded it? It's incredibly torquey so I didn't think I was underpowered.

Or is this just bad luck?
 
Not sure on the engine internals, BUT 3.31 gears/32" tires/loaded down/I am presuming you are using overdrive, are you excessively lugging the engine, i.e. too low RPM for speed/loads?

I have been running 258/4.0 with Mopar MPI/4.10 gears/33" tires/T5 and AX15. I typically cruise at 70-75 mph running around 2500 RPM. No valve issues. Good power, 14-15 mpg. My Jeep is heavy and I carry a bunch of junk with me.

My green Scrambler has 31" tires/258 with MPI/3.31 gears/T5. Fifth gear is usable but I still wish it had a slightly deeper axle gear. Not major, maybe 3.54 or 3.73 at the most. This Jeep averages 16-17mpg mixed use driving, good power in 5th gear.
 
Not sure on the engine internals, BUT 3.31 gears/32" tires/loaded down/I am presuming you are using overdrive, are you excessively lugging the engine, i.e. too low RPM for speed/loads?

I have been running 258/4.0 with Mopar MPI/4.10 gears/33" tires/T5 and AX15. I typically cruise at 70-75 mph running around 2500 RPM. No valve issues. Good power, 14-15 mpg. My Jeep is heavy and I carry a bunch of junk with me.

My green Scrambler has 31" tires/258 with MPI/3.31 gears/T5. Fifth gear is usable but I still wish it had a slightly deeper axle gear. Not major, maybe 3.54 or 3.73 at the most. This Jeep averages 16-17mpg mixed use driving, good power in 5th gear.
Yes, I have been worried about lugging. However, I do not use overdrive unless going downhill or the RPM's are above 2000+. It's hard to tell if this engine is lugging because it never "knocks/pings" or makes noise.

Yes, your green Scrambler sounds like my situation. I usually enjoy 17-18mpg going around 65mph and 2200 rpms. I'n not sure I want 4.10's because I'd rather get my crawl ratio in the transfer case ans still be able to cruise on the freeway without higher rpms...
 
Here's another way to ask this question: It seems like a factory 4.0L can run 200k-300k without ever having a valve (or other major problem). It also seems like guys who modify their engines are often running into problems and breakdowns. Is it generally true that this modification (4.0L head and MPI on older 258 block) increases engine problems compared to a factory 4.0 that has never been torn into?
 
Here's another way to ask this question: It seems like a factory 4.0L can run 200k-300k without ever having a valve (or other major problem). It also seems like guys who modify their engines are often running into problems and breakdowns. Is it generally true that this modification (4.0L head and MPI on older 258 block) increases engine problems compared to a factory 4.0 that has never been torn into?
That's been my observed experience. Stock 258 or stock 4.0 last forever. Mixing and matching parts sometimes not to great.

I purchased a brand new 2005 TJ Rubicon, put 165,000 miles on engine, no internal engine issues.

Purchased a 2005 LJ Rubicon with 20k miles on it. Sold it with 140k miles no issues.

4.0 in my Red Scrambler has about 70k miles with no issues. Well, timing chain had excessive slack, noticed this when installing a new oil pan gasket, so I swapped in a new chain.

Maybe look at your timing chain? I couldn't get a single roller chain to work without excess slack so I swapped in a more expensive Cloyes double roller chain set up.

Might be worth looking at your timing chain?
 
258 /T176 33” tires 3.54 gears. Enough power. Just wish I had a 5 speed transmission.
My last CJ7 had 258/t176, 31" tires, 3.31 gears and had plenty of power also. Was a soft top Jeep it entire life no added armor/bumpers. With alot of added weight, I would have wanted better gears for sure.
 
My last CJ7 had 258/t176, 31" tires, 3.31 gears and had plenty of power also. Was a soft top Jeep it entire life no added armor/bumpers. With alot of added weight, I would have wanted better gears for sure.

Andy has factory 3.54 gears since his Jeep was a factory 2.5 four cylinder. The 3.54s give a slightly noticeable bump over the more common 3.31 gears.
 
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