Dropped sump on my high-mileage Transit 2.2 TDCi and found a hairline crack in the block between cylinders 2-3 (water jacket side). No overheating history, but coolant in oil now. Can these be welded or sleeved, or is the block toast?
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Small cracks in cast iron blocks can sometimes be repaired with specialist welding (Ni-rod or similar) or stitching if not structural, but on commercial vans with high stress, it's risky- crack can propagate under load. Many go for used/reconditioned blocks. I had a similar find on a Transit- opted for a low-mile donor block. Found a compatible short block assembly and individual crankshaft parts at https://elartcom.eu/categories/engine-block-and-crankshaft-141 - they list block-related components and some reman cranks for Ford Transit engines. Transferred my head/pans over- saved vs full new engine. If welding, get a pro engine shop opinion first. Their category is useful for sourcing spares if rebuilding or swapping.