Lesson - keep ALL holes plugged!!!

[lacton]

Went to replace the plug that goes above the plastic rod (00M12 kit) while the front tensioner was removed. The plug fell off the torx bit and as Murphy's Law would have it, the plug dropped into the tensioner hole.

It looks like removing the front cover is now the next step. Might as well replace the front chain guide while I'm at it. Is it possible the plug could still be somewhere in the cylinder head? Somehow I don't think it's going to be that easy.

 

[2000StreetRod]

bad luck!

I believe the galley plug is ferrous. If so, I'd try a magnet on a flexible shaft. They are available from auto parts stores. The plug could be wedged between the chain and the head but not likely. You can replace the primary tensioner and guide without retiming the camshafts: SOHC V6 Timing Chain Inspection & Repair

 

[lacton]

Actually, it looked like it was made of brass. Right now, I'm looking at all options I have. I'm not at all thrilled with this engine design....had I known then what I know now, I would have gone with the standard V6 or V8....not the SOHC V6.

The engine has 200K on it and I'm not sure how much longer it's going to hang in there. Doing a semi-teardown just to find that plug doesn't make much sense on an engine that is at, or nearly at, a necessary overhaul. Although I can do the job, it may not be the best thing to do at this point.

Maybe we should cut our losses and get something reliable. My Honda Civic has 350K on the odometer, gets 45-50mpg and NOTHING has gone wrong with it.

 

[2000StreetRod]

brass plug?

You have a new galley plug in the kit. It's easy enough to check with a magnet. I doubt that it's a brass plug.

I'll be the first to agree that the SOHC V6 is a poor design for reliability and serviceability. It's aggravating that the engine has to be pulled to replace the rear timing chain or guide assembly. However, when I pulled my engine to replace the broken rear guide at 151,000 miles the compression was still good and the one main bearing I checked was in good shape.

It's unfair to compare a Honda Civic to a Ford Explorer. They are in entirely different categories. Anyway, would you consider selling your Explorer without first finding the lost galley plug? That would be irresponsible unless you disclosed the fact to prospective buyers.

 

[lacton]

That was the new galley plug that down the hole. I'm going to try to locate the plug anyway....won't make matters any worse by doing so and I would never pass that on to someone else without their knowing.

Maybe I should start by removing the lower pan and hope it made it all the way down, but it's probably sitting on top of the upper pan....can I get in there with the front cover removed? Next, the valve cover since it doesn't seem very involved, and then the front cover. But whatever it takes I've got to locate this thing....I'm not too keen to starting an engine with a loose part somewhere inside.

Sorry if it sounded like I was comparing the Explorer to a Civic....it's just hard to go from one vehicle that never has a problem to another that has enough problems for both. To be honest, I'm considering following your thread when you pulled the engine and replaced the chain and guide assemblies. That might be the best route to go....at 200K I can't imagine the originals have much life left in them and I did find a few small pieces of plastic in the lower pan when I replaced it.

It's been awhile but speaking of rotten engines....the last time I pulled one was when I replaced one of those awful GM 5.7 liter converted-gas diesels (worst engine EVER to be dumped on the public) with a 6.2 liter for-real diesel in our Impala war-wagon. That thing flew!

 

[2000StreetRod]

not much clearance

There is not a much clearance between the head and the cassette. The plug may be trapped in the head and you may be able to retrieve it after removing the valve cover.

There are only a few small holes in the front of the block cradle. There's a good chance if the plug fell past the timing cover opening then it is laying on top of the block cradle. Other forum members have retrieved pieces of their failed left guide assembly by reaching thru the removed timing cover opening.

 

[lacton]

I hope it goes that way....but maybe this happened for a reason, although I've never been much of a believer of "things happening for a reason". With that much mileage on the engine, the chains and guides cannot have much life left and replacing them is the best option.

I have to admit we've always thought highly of our Explorer. It's the most forgiving vehicle I've ever owned and seems to put up with just about everything that can be thrown at it. Everything except stupidity....such as not plugging exposed holes. Too bad it can't reverse the law of gravity.

Also, your posts and this forum are extremely helpful.

 

[lacton]

You were right! I put the project aside for the past 3 weeks because I was so frustrated at what happened with the little plug....there's no rush. Well, today I pulled the valve cover off and couldn't see the plug anywhere so I pushed in on the chain guide to get the chain out of the way and with a flashlight could see it way down near the jackshaft sprocket setting between the chain and engine block.

Whoever invented those reach rods with a magnet on the end must have done the same I did and dropped something down inside something else. The plug is ferrous, just cadmium plated and looks like brass.

The plug has been recovered and I'm ready to button it back up. However, the chain guides don't look so good. I found a piece (end) of a guide resting on the cylinder head next to the valves. Maybe, the engine will come out after all....but that's something I'll tackle next year.