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SOHC Engine Removal/Rebuild/Install - Done!

Are you gonna use some kind of head gasket sealant on your head gaskets like copper spray just for good measure

I seen dem pros using it on the tv lol
 



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Are you gonna use some kind of head gasket sealant on your head gaskets like copper spray just for good measure

I seen dem pros using it on the tv lol

No. It should not be necessary to use any kind of sealant on head gaskets.
 






Conflicting information...

In making sure I have all the TTY bolts I need to replace, I see where the front and rear jack shaft bolts are not indicated as TTY, but the torque spec talks about tightening to so many foot pounds and then turn them so many degrees. To err on the safe side I decided to order new jack shaft bolts Ford OE. The two only came to around $25 so I figured better safe than sorry.
 






Conflicting information...

In making sure I have all the TTY bolts I need to replace, I see where the front and rear jack shaft bolts are not indicated as TTY, but the torque spec talks about tightening to so many foot pounds and then turn them so many degrees. To err on the safe side I decided to order new jack shaft bolts Ford OE. The two only came to around $25 so I figured better safe than sorry.
Smart

Btw they are tty
 






Smart

Btw they are tty

Also ordered today...
Ford fuel injector adaptors (6) F77Z9G512AA $26.76
Ford Jack shaft plug/seal F77Z6026AB $20.44

Ordering soon...
Ford OE oil pump XL2Z-6600-AA eBay w/free shipping $44.88
Motorcraft Timing chain kit 4L2Z6M290AA 7U3Z6A257A $528.00
OTC 6488 cam installation tool kit new $201 on Amazon, used eBay $ ?
 












Hmmm I would have thought it would be more

It's actually quite a bit less expensive than the Melling STD pump and I don't need to also buy a new pickup & screen ($42) if I stay with the Ford OE pump. Tasca Ford had the OE pump for around $10 more + shipping.
 






Pics of my reman'd heads. Now sprayed down with WD40 and bagged to prevent rusting.

UorXTSS.jpg

AP9QFzg.jpg
 






Minor updates today:
I'm finally done with the hospital and doctors. I'm not an emoji kind of guy, but... :bounce:

Today I decided to drain my fuel tank of the more than year-old 1/2 tank of gas it had in it. Rather than pumping it dry with the fuel pump I removed the left rear wheel, which gave me excellent access to where the filler hose connects to the tank. I removed the filler hose an inserted a piece of clear 3/8" OD tubing into the tank. The metal filler nipple has a gentle 90 degree bend it in once it enters the tank, so the 3/8" line ends up going straight to the bottom corner of the tank. The front and rear of the truck were already up on safety stands, but I raised the front slightly so that all the fuel flowed to the rear of the tank. Next, I got out all my plastic gas cans (4 containers with a total of 12 gallons capacity) and started siphoning. Using the clear tubing makes sure I don't get a mouthful of gas. It took a little while, but after about 40 mins I got out about 11 gallons before the siphon hose ran dry. Then I reinstalled the fill hose. When the time comes to start the engine I will add fresh fuel and flush out the fuel line and filter before the first startup.

I had added Sta-bil fuel stabilizer to the fuel last Summer, but as it was already at least 6 months old then (and was 10% ethanol fuel) I didn't trust it. I wondered whether the fuel I'd removed was still any good. It smelled okay, so I decided to test it to see how volatile it was. It wasn't a very scientific test, but I had a bunch of paper bags in my 50 gal burn barrel, which has 1" air holes drilled around it's lower circumference, so I poured a 1/2 cup or so of the old fuel on the paper bags and used my propane had torch to light it from the bottom being careful not to have my face anywhere near the top of the barrel (safety third) and whoopf! the paper bags went up as if I'd used fresh fuel. So I guess the fuel is still okay. This is good news for 2 reasons.... Firstly, I don't have to figure out how to responsibly dispose of 11 gals of bad gasoline and secondly I don't have to waste $25-$30 dollars worth of fuel I can still use. I plan to introduce it slowly (just to be safe) into our old 2000 Mountaineer and burn it.

Next I removed my hood (which isn't currently bolted on) just to put fresh plastic bags over things I don't want animals or insects getting into. I'd used plastic grocery bags on things when I pulled the engine out back in October, but they didn't hold up very well. This time I used zip-lock bags and wire tie-wraps. When the weather gets nicer I plan to power-wash the engine compartment, which isn't terribly dirty but I might as well clean it while the engine is out. I was going to reinstall the hood on its hinges temporarily to make for easier access to the engine compartment, but I didn't reinstall the hood bolts in their bolt holes and I didn't feel like looking for the marked baggy, so I just laid the hood back on for now. I need to buy a new tube of dielectric grease to pack all the electrical connectors to keep insects and water out of them until reassembly.

One thing I decided to address, which caused me a big PITA during the engine removal, was the ground wire that bolts to the back of the left cyl head and then to a stud/bolt on the wiper motor. For some reason the nut that holds the ground wire to the stud would not come off and when the stud started to turn the wire spun with it, hitting the edge of the cowl. Today I spend a good 20 mins trying to get that nut loose, but there's no way to hold the stud to stop it from spinning. I finally had to bend the wire eye over at 90 degrees and take it off with the stud. Then I held the stud with vice grips, sprayed WD40 on the nut and got the nut and wire off. What a pain!

Right now I'm waiting on nicer/warmer weather, so I can start cleaning the engine block and other parts and for ordered parts to arrive so that I can begin engine reassembly. I guess I need to go to Walmart and buy another large container of Purple Power. Yesterday I found a nice set of assorted roll-lock disks on clearance at Tractor Supply, so they will be helpful in cleaning gasket surfaces.
 






Happy to hear the doctors are over I hate doctors

Good progress
I've been following this thread :usa:
 






Congrats on the interesting project of fuel removal!

Glad the Doctors are done.
 






Yeah, I won't miss having the Xray's and MRI's, having a PICC line in my arm for 6 weeks, the 42 daily trips to the hospital for infusions, the weekly blood work, and the weekly appts with specialists, but at least I didn't end up needing the 60 Hyperbaric therapy treatments they though I might have needed. Now all I have to deal with are all the medical bills.

I did learn an important lesson though... Don't let stuff go thinking it will get better on its own. As we age things don't work so well anymore.
 






Oh, BTW - I forgot to mention I used my new Milwaukee M18 Fuel 1/2" impact wrench, that I'd bought myself for Christmas, to remove my rear tire before draining my fuel tank. What a fantastic tool! It took off those lug nuts, which were torqued to 100 foot pounds, like nothing. No dragging out the air compressor, hooking up and extension cord, listening to a noisy compressor running, or fighting with a tangled air hose just to remove a wheel. Just zip, zip, zip and the lugs were off. I just wish I'd bought this tool sooner.
 






Parts have started arriving. So far I've received...
- Fel-Pro full gasket/seal set
- New harmonic balancer
- New TTY harmonic balancer bolt
- Jack shaft rear block plug/seal
- Ford TTY front and rear jack shaft bolts
- Ford fuel Injector adapters
- Fel-Pro TTY cylinder head bolts

Next to be ordered,,,
- Motorcraft timing chain kit
- Ford OE oil pump
- Cam timing tool kit
- Torque angle gauge

I'd hoped to start prepping/cleaning the engine block this week, but after today the winter weather is returning for at least the next week or so. I'm itching to get started.
 






He'll yea
Fun time waiting for parts :banghead:

But then again I'm young lol
 






Minor Update:
First day in a while it's been dry and warm enough to work on my engine (and we're supposed to get like 5"-6" of rain this coming week). I'm so sick of rain and on the rare occasion we get a couple of dry days it's too cold to do anything. Today I worked on cleaning up the top of the engine block, pistons and cylinder bores. The 3 cylinders/pistons on bank 2 cleaned up really easily with just some lacquer thinner. I think this was the bank with cracks between the cyl 4, 5 and 6 valve seats, maybe they were getting steam-cleaned. On the bank 1 pistons one cleaned up easily but I had to scrape carbon off two of them. This head only had one crack between the valves so I guess only one piston was getting steam cleaned. All the parts I've ordered so far have come in, but until I can get my engine block completely clean I figure there's no point in ordering the remaining parts I'll need at this time. For now, after cleaning, I coated everything w/WD40 to prevent rusting and stuck the engine in a plastic bag.

I'm amazed that my cylinder bores have no ring ridges at the top, considering this truck had about 220,000 miles on it and that the previous owner almost never performed any maintenance . The lack of a cylinder bore ridge and the fact that it's a balance shaft engine in a 2WD make me wonder if this isn't a replacement engine. Maybe Ford will know by VIN because if this engine was replaced it must have been done by a dealer as there is no visual indication that anything had ever been disturbed.

Opinions?
I was planning on not hooking up the balance shaft chain on my engine, but it looks like the Ford OEM timing chain kit comes with the balance shaft chain, guide and tensioner. Does anyone have an opinion as to whether I should hook up the balancer? I've read that it can cause problems and that it isn't necessary on the 2WD trucks. The only reason I'm considering hooking up the balance shaft is that this engine has always run very smoothly, despite it's cracked heads and broken timing chain components.
 






Hey Koda. I’m really enjoying reading about your progress on this rebuild.

I don’t have enough experience to have opinion on the balance shaft but I’ve also read that it’s not necessary on the 2WD.

I hear what you’re saying about the rain! I’m in middle Tennessee and my yard has not been truly dry since Thanksgiving.
 






Opinions?
I was planning on not hooking up the balance shaft chain on my engine, but it looks like the Ford OEM timing chain kit comes with the balance shaft chain, guide and tensioner. Does anyone have an opinion as to whether I should hook up the balancer? I've read that it can cause problems and that it isn't necessary on the 2WD trucks. The only reason I'm considering hooking up the balance shaft is that this engine has always run very smoothly, despite it's cracked heads and broken timing chain components.
I say it's just asking for problems
 






I say it's just asking for problems

You're probably correct. More moving parts, more complexity, more failure points.
 



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I might keep the balance shaft going if you have the parts, and time it properly. I didn't pay the extra $75ish for the bigger kit to get those, so I plan to cut the chain on mine.

The balance shaft tensioner is very fragile, my OEM one broke on it's own at some point while I took the rest apart. It was intact when I first got the timing cover off(77,450 miles), but I noticed the tensioner(little spring steel part) broken and on the floor a day later before I unbolted anything in there. My balance shaft was way out of time too, no idea how it got that way. It was a pain to re-time it as I recall, it was a few revolutions out to get it back close and line up the dots/marks.
 






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