20180522_192300.jpg
233 hits | 113.21 KB | Posted: 5/28/18
Tank & axle RHS just after pressure-washing.

Before:

(Posted in: The Carcass)

20180522_192147.jpg
255 hits | 104.31 KB | Posted: 5/28/18
Engine LHS just after pressure-washing.

Before:


Note that it still has the red (flaming) SCDS on the...
(Posted in: The Carcass)

20180522_192159.jpg
244 hits | 103.27 KB | Posted: 5/28/18
Trans & t-case LHS just after pressure-washing.

Before:

(Posted in: The Carcass)

20180522_192211.jpg
234 hits | 98.9 KB | Posted: 5/28/18
Tank & axle LHS just after pressure-washing.

Before:

(Posted in: The Carcass)

20180526_143054.jpg
239 hits | 115.92 KB | Posted: 5/28/18
Emptying the tank into mine, using an old fuel pump (probably from a Crown Vic tank), the battery pack from my cheapo cordless impact, & some old Bronco fuel lines.
(Posted in: The Carcass)

20180528_120034.jpg
228 hits | 126.52 KB | Posted: 5/28/18
It's getting close...
(Posted in: The Carcass)

BodyMtLH3.jpg
230 hits | 68.86 KB | Posted: 5/28/18
I couldn't hammer this body mount sleeve apart, so I soaked it for a few days and then hammered it together. ...a little too hard, I guess.
(Posted in: The Carcass)

20180527_192357.jpg
253 hits | 55.74 KB | Posted: 5/28/18
The rear main & bore plugs look OK, so I'll probably leave the seal alone.

I assume that's the block SN just below the LHS head, but it's too rusty to read.

That's a little dab of orange paint at the 1:30 position indicating the flexplate alignment...
(Posted in: The Carcass)

20180528_120151.jpg
262 hits | 83.27 KB | Posted: 5/28/18
After the last of the oil drains out, I'll pull the manifolds, timing cover, & pan; and paint everything like I did the '93's engine.
(Posted in: The Carcass)

20180528_120206.jpg
281 hits | 75.49 KB | Posted: 5/28/18
The exhaust manifold has to come off to get the broken bolt out, so I'll pull both & sandblast/paint them like the '93's engine.

[url=https://www.supermotors.net/registry/media/1136928][img]https://www.supermotors.net/getfile/1136928/thumbnail/20180...
(Posted in: The Carcass)

20180529_183053.jpg
268 hits | 82.84 KB | Posted: 5/29/18
The L axle beam is substantially bent, but the R looks OK.
(Posted in: The Carcass)

20180529_180733.jpg
326 hits | 109.08 KB | Posted: 5/29/18
With the front suspension unloaded, I was able to flip the exhaust to work it over the axle, and slide it out the front of the frame. The bolts at the muffler flange are rust-siezed, so I plan to grind the heads off, soak them in penetrant for a wee...
(Posted in: The Carcass)

20180531_160604.jpg
318 hits | 97.97 KB | Posted: 6/1/18
I had to use my thinnest open wrench to back up the exhaust shield nuts. 2 of the bolts were broken.


(Posted in: The Carcass)

96Dist58.jpg
322 hits | 65.31 KB | Posted: 6/1/18
Distributor tag & drive gear for roller cam.

Eventually, I taped off the tag & gear, sandblasted the Aluminum, and clearcoated it before installation.
(Posted in: The Carcass)

20180531_184318.jpg
627 hits | 94.82 KB | Posted: 6/1/18
The missing chunk of timing cover was resting on the splash shelf. The milk in the oil pan is just from the pressure washing. See the NEXT several pics...

The timing cover gasket was on the verge of failure, indicated by the corrosion around the co...
(Posted in: The Carcass)

20180531_192600.jpg
574 hits | 131.22 KB | Posted: 6/1/18
I was amazed to find these original valve cover gaskets are steel, with just a thin inner lip of rubber. They adhered VERY well to the covers & heads. I'm seriously considering reusing them, if I can't buy identical replacements. The intake gasket...
(Posted in: The Carcass)

TimingChainSlack.jpg
308 hits | 94.45 KB | Posted: 6/1/18
The chain has barely any more slack than a new one would. Probably less than 2 degrees.

Odo 299,062.2mi
(Posted in: The Carcass)

20180601_145936.jpg
312 hits | 107.7 KB | Posted: 6/1/18
The oil pump pickup was clear, but it's also clean now. The oil pan gasket appears to be reusable. But there are still 2 broken bolts in each head that I have to extract...
(Posted in: The Carcass)

20180601_180411.jpg
323 hits | 90.41 KB | Posted: 6/1/18
I cut these bolt heads off so there would be more to work with when I try to extract them. But first, they'll soak in penetrant for a week or 3...
(Posted in: The Carcass)

20180611_093422.jpg
420 hits | 109 KB | Posted: 6/11/18
After spraying this Dorman 635-100 with DupliColor DE1650, I put some Hylomar on the (supplied) front main & tapped it in. Then I sprayed [url=https://w...
(Posted in: The Carcass)

20180611_165506.jpg
547 hits | 55.52 KB | Posted: 6/11/18
I've been procrastinating, but today I went after these intake bolts. They've been soaking in penetrant for about a week, from both sides, but they're still too tight to drive out. So I'm starting with a die grinder to flatten the top faces, a cente...
(Posted in: The Carcass)

20180611_170437.jpg
309 hits | 97.2 KB | Posted: 6/11/18
I drilled through, to check that the hole was centered & aligned, and stepped up 1/32" at a time to 1/4", which I drilled left-handed.

See the PREVious & NEXT few pics...
(Posted in: The Carcass)

20180611_174900.jpg
324 hits | 67.58 KB | Posted: 6/11/18
Unfortunately, the bolt still didn't unscrew, but it was so thin that most of the bolt thread peeled out of the head's threads.

See the PREVious & NEXT few pics...
(Posted in: The Carcass)

20180611_175314.jpg
308 hits | 89 KB | Posted: 6/11/18
I chased the remaining bolt thread & corrosion out with a tap, and cleaned the pocket at the top.

See the PREVious & NEXT few pics...
(Posted in: The Carcass)

20180611_180222.jpg
316 hits | 68.18 KB | Posted: 6/11/18
The driver's side bolt sheared at an angle, making it harder to find center. I had to dig the corrosion out of the pocket first, die-grind the top flat, punch center, and then drill as before.

See the PREVious & NEXT few pics...
(Posted in: The Carcass)

20180611_190230.jpg
346 hits | 68.78 KB | Posted: 6/11/18
The hole was very slightly off-center near the bottom, but not enough to damage the head. The bolt will still hold well.

See the PREVious five pics...
(Posted in: The Carcass)

20180703_203332.jpg
341 hits | 84.99 KB | Posted: 7/19/18
After a few days soaking with penetrant, I punched, drilled, & extracted the 2 ex.man. bolts that had sheared. These Irwin straight-flute extractors are good, but they only seem to work once. Next ti...
(Posted in: The Carcass)

20180709_173816.jpg
1005 hits | 74.68 KB | Posted: 7/19/18
These '96 water pump bolts are slightly different from the '93's. The pump is a new Ford F3TZ-8501-C, aka MotorCraft PW254.

[url=https://www.supermotors....
(Posted in: The Carcass)

20180723_110627.jpg
324 hits | 73.8 KB | Posted: 7/23/18
Original high-temperature studs & nuts aren't available now, so I'll be using these Dorman 03135 after I sandblast & paint the manifolds, & have them planed.

See also:
[url=https://www.supermotors.net...
(Posted in: The Carcass)

20180723_165348.jpg
285 hits | 93.44 KB | Posted: 8/2/18
New Motorcraft SP-501 plugs, of course. These are ASF-32P, as specified on the VECI label.

[url=https://www.supermotors.net/registry/media/1133854_1][img]https://www.supermotors.net/getfile/1133854/th...
(Posted in: The Carcass)

20180728_153349.jpg
317 hits | 94.41 KB | Posted: 8/2/18
I didn't realize this grommet would be chinese when I ordered it, but my local Ford doesn't sell it (possibly E7AZ-6A892-A).
0.715 In. ID x 1.440 In. OD x 0.493 In. Thk.

The PCV valve is [url=https://www.amazon.com/dp/B000C5FJG8]MotorCraft EV-68[/ur...
(Posted in: The Carcass)

20180802_162144.jpg
272 hits | 107.66 KB | Posted: 8/2/18
These have been soaking for a couple of months, but they were still tight. 2 came out this way...

See the NEXT pic.
(Posted in: The Carcass)

20180802_170114.jpg
294 hits | 76.22 KB | Posted: 8/2/18
Even after a couple months in PB Blaster, one sheared & required drilling before going out forward.
(Posted in: The Carcass)

20180723_185517.jpg
300 hits | 94.94 KB | Posted: 8/2/18
The fuel rail is pretty scruffy, so...


(Posted in: The Carcass)

20180802_200258.jpg
339 hits | 91.41 KB | Posted: 8/2/18
I polished the chrome & stainless (FPR) with fine steel wool, and clearcoated the chrome with DE1636. I rinsed the injectors with carb cleaner, polished the bodies, oiled the O-rings, and stabbed them ...
(Posted in: The Carcass)

TstatBolt.jpg
324 hits | 71.69 KB | Posted: 10/8/18
Drilling a hole into this blind boss to let some penetrating oil soak for a few days paid off. This bolt was the easiest (of the 8 that broke on this truck) to extract because it was sticking out enough to grab with vise-grips, and simply back out. ...
(Posted in: The Carcass)

20181210_174534.jpg
446 hits | 71.1 KB | Posted: 12/12/18
After sandblasting, planing, painting (Rustoleum High Heat Silver), & new flange hardware (cheapo aftermarket because there were no others at the time); I applied red silicone & installed the manifolds. This one is significantly warped - the front p...
(Posted in: The Carcass)

20181211_110046.jpg
444 hits | 77.88 KB | Posted: 12/12/18
Eventually, I got all the exhaust manifold bolts in (with nickel anti-seize) & torqued. Then I added the heat shields & accessory nuts.

[url=https://www.supermotors.net/registry/media/1055473][img]https://www.supermotors.net/getfile/1055473/thumbna...
(Posted in: The Carcass)

20181211_110100.jpg
363 hits | 81.63 KB | Posted: 12/12/18
Eventually, I got all the bolts in (with nickel anti-seize) & torqued. Then I added the heat shields & accessory nuts.

[url=https://www.supermotors.net/registry/media/1055473][img]https://www.supermotors.net/getfile/1055473/thumbnail/exhmanbolt.jpg...
(Posted in: The Carcass)

20181212_144125.jpg
342 hits | 83.32 KB | Posted: 12/14/18
After mounting the plenum, the throttle body (carefully sandblasted & clearcoated) went on with a new gasket.
(Posted in: The Carcass)

20181212_144717.jpg
332 hits | 79.21 KB | Posted: 12/14/18
Original '96 5.8L IAC (F4TE-9F715-AA) built 1996 Feb. 07 3rd shift 1st line
(Posted in: The Carcass)

MAF96.jpg
500 hits | 68.77 KB | Posted: 12/14/18
Original '96 5.8L MAF sensor (F5UF-12B579-BA, built 1996 Feb.19 - 2nd shift) & venturi

One of the screw heads (Tamper Torx 15) is epoxy-filled to prevent removal of the sensor from the body.

Possible replacement PN: [url=https://www.amazon.com/dp/B...
(Posted in: The Carcass)

20181220_110051.jpg
409 hits | 104.42 KB | Posted: 12/28/18
Now that my sandblaster is working so well, I finished the accessory brackets, pulleys, & Saginaw. I painted the tensioner's LH-threaded bolt head yellow.

Odo 299,062.2mi
(Posted in: The Carcass)

20181227_154706.jpg
344 hits | 80.26 KB | Posted: 12/28/18
It's a cool rainy day, so I put the exterior wiring harness sections outside, and washed them with PurplePower. I could pressure-wash them, but I assume it would blast off most of the wrapping. So I'll just leave them outside for a few more rain/PP...
(Posted in: The Carcass)

20190108_1423weight.jpg
496 hits | 101.83 KB | Posted: 1/20/19
My new toy is a 660-lb (300 kg) digital hanging scale, which is interesting to use on the larger parts. I never lifted weights, so I didn't realize how much I had been doing by hand.
IF THE IMAGE IS TOO...
(Posted in: The Carcass)