20200225_172515.jpg
126 hits | 106.65 KB | Posted: 2/25/20
You wouldn't think I had already spent 2 hours washing this truck, but the few clean spots give it away. The rust on the torque converter pilot suggests that there has been water in the bellhousing for some time.

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20200225_182904.jpg
158 hits | 100.58 KB | Posted: 2/25/20
We already knew the engine mounts were broken, and that the pan gasket needed replacement, and that the valve cover gaskets had problems. But I didn't realize how bad the left VCG was leaking. I have to wonder if the oil journals in the head are blo...
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20200225_192628.jpg
114 hits | 69.76 KB | Posted: 2/25/20
I hand-washed the engine wiring & vacuum harnesses, rather than risk shredding them with the pressure washer.
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20200226_144415.jpg
172 hits | 97.84 KB | Posted: 2/26/20
It came cleaner than I expected, but it took about 2 hours in 40-degree wind. The pressure washer went through a full tank of gas.

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20200226_143926.jpg
104 hits | 76.19 KB | Posted: 2/26/20
Before & after.
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20200226_160824.jpg
99 hits | 68.43 KB | Posted: 2/26/20
This leak was easy to see & fill.
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20200226_160122.jpg
102 hits | 48.04 KB | Posted: 2/26/20
These 2 leaks were only visible with a mirror. I had to weld them through the slot in the frame.
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20200227_134659.jpg
155 hits | 73.07 KB | Posted: 2/27/20
Nuff sed.


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20200227_134854.jpg
123 hits | 72.6 KB | Posted: 2/27/20
Upskirt porn
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20200227_134940.jpg
479 hits | 87.19 KB | Posted: 2/27/20
Timing cover gasket details

It looks in such good condition, I don't really want to change it. But it's so old that I hate to put the engine back in when it's only a couple hundred in additional labor from this point. The parts needed are: timing co...
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20200227_135045.jpg
132 hits | 81.62 KB | Posted: 2/27/20
I trimmed the overhanging silicone from the back of the valley.
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20200227_135156.jpg
150 hits | 45.77 KB | Posted: 2/27/20
Intake manifold gasket details
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20200227_142422.jpg
126 hits | 46.67 KB | Posted: 2/27/20
Flexplate & shim plate painted.


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20200227_171355.jpg
127 hits | 63.9 KB | Posted: 2/27/20
I tightened two exhaust manifold bolts that were very loose; a few others, slightly. Since I didn't find any leaks here with the engine running, I don't think the manifolds are warped - probably because they don't have gaskets (which is proper).
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20200227_175740.jpg
163 hits | 61.16 KB | Posted: 2/27/20
After painting the back end of the block, I changed the rear main seal.


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20200229_111753.jpg
555 hits | 80.16 KB | Posted: 2/29/20
I turned the crank forward to 0 degrees, set a pointer wire on the distributor shaft, then turned the crank back just until the wire started to move to measure timing chain slack. 8 degrees is pretty high, which is another reason I think this engine ...
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20200302_095059.jpg
144 hits | 78.59 KB | Posted: 3/2/20
The water pump itself looks much better than I expected. But its backing plate is the worst I've ever seen. And I've never found gray sludge in the water pump's blind cavities.
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20200302_104852.jpg
290 hits | 95.94 KB | Posted: 3/2/20
This is 8 degrees of slack. I assume this is why someone thought the distributor rotor needed a paper shim.

The dowel sleeve that stayed in the block was easy to remove. The one that stayed in the timing cover was seized.

I didn't realize that any...
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20200302_145011.jpg
141 hits | 80.25 KB | Posted: 3/2/20
Just before removing the timing cover, I painted the block. After removing the timing cover gasket & gears, I polished the gasket surface.
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20200302_154444.jpg
125 hits | 60.53 KB | Posted: 3/2/20
The only supplier for a replacement dowel I've found so far is:
https://lmr.com/item/388192SK/1979-95-Mustang-Timing-Cover-Dowels
But I might have one in my junkpile...
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20200302_164422.jpg
149 hits | 90.96 KB | Posted: 3/2/20
After a lot of parts-washing & sandblasting, I painted all the timing cover parts.
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20200302_143400.jpg
119 hits | 68.68 KB | Posted: 3/2/20
As Ford & most other makers recommend, I always clean the wheel mounting surfaces.
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20200304_204519.jpg
151 hits | 54.96 KB | Posted: 3/6/20
The EGR fitting was too rusty to reuse, and its threads stripped when I removed it from the manifold. So since I don't have & can't find a tap that fits it, I had to make the new fitting a thread-chaser. I ran the old fitting in several times to bre...
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20200305_104419.jpg
420 hits | 97.96 KB | Posted: 3/6/20
The gears are in exactly the same position, with all the slack on the driver's side, so the additional tooth showing with the new gears means the chain is tighter.
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20200306_160309.jpg
342 hits | 88.68 KB | Posted: 3/6/20
After Copper-Coating the new timing cover gasket on, I installed it (with a used dowel tube) & the oil pan. The oil pan corners also got some Hylomar.
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20200306_164103.jpg
647 hits | 81.99 KB | Posted: 3/6/20
The Left pivot bushing (for the Right axle beam) was powdered. The other one was in better condition, but it also got replaced. Both sleeves required air-chiseling to remove.

[url=https://www.supermotors.net/registry/media/1036242][img]https://www.s...
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20200307_143234.jpg
340 hits | 67.22 KB | Posted: 3/7/20
Poly axle pivot bushings are pressed in.
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20200307_143310.jpg
240 hits | 67.83 KB | Posted: 3/7/20
Right camber cam in
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20200307_170020.jpg
139 hits | 102.96 KB | Posted: 3/7/20
All 6 cap screws were seized, but the internals weren't as bad as I expected. It looks like the wrong grease was used, but the bearings (even the spindle bearings) are undamaged.
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20200307_190231.jpg
134 hits | 72.33 KB | Posted: 3/7/20
All the steering parts went into the washer because they were too nasty to handle. The pitman arm has an oversized hub, so I'll have to use a different puller on it.
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20200307_174843.jpg
97 hits | 97.27 KB | Posted: 3/7/20
While changing the rear seat strike bar, I also straightened its cup, and removed ANOTHER dirt-dauber nest.
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20200307_153946.jpg
340 hits | 87.1 KB | Posted: 3/7/20
The Right lower ball joint nut wasn't tight; not even finger-tight. And although it had been wallowing in the bore enough to wear threads into it, the bore was undamaged. I used the torch to release the old ball joints, and let the new ones in with l...
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20200308_210709.jpg
148 hits | 88.56 KB | Posted: 3/8/20
Driving out the spindle bearing is always a PITA, but this improvised drift made it much easier. Between the hits, I rotated the bolt around the bearing to drive it out evenly.
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20200308_211623.jpg
184 hits | 93.23 KB | Posted: 3/8/20
The engine & bay are almost ready for each other. The steering box has been replaced, and the (clean) intermediate shaft's telescope joint is greased. Most of the grime is scraped off the crossmember.
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20200308_164002.jpg
123 hits | 55.2 KB | Posted: 3/8/20
This telescope seal for the intermediate steering shaft shows why common PSF is the wrong fluid for the PS system. Only use ATF.
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20200309_195802.jpg
274 hits | 86.99 KB | Posted: 3/9/20
I had to refill my grease gun, but the hub & spindle are as full as possible to keep water out, and to keep the bearings lubed. Although the brakes look rough, they appear to be OK, with plenty of miles left.
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20200312_161745.jpg
117 hits | 55.63 KB | Posted: 3/12/20
I set the engine back into the bay.
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20200313_103051.jpg
134 hits | 84.43 KB | Posted: 3/13/20
The exhaust was built while the engine mounts were broken, and the trans mount wasn't neutralized. And it has too many hangers, preventing it from shifting as it needs to. The tailpipes also contact the leaves during full droop (as when it's on the l...
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20200313_111645.jpg
184 hits | 74.43 KB | Posted: 3/13/20
I had a lot of trouble making the bellhousing mate up to the block, until I found out why. Someone turned the transmission mount backward. The starter bolts were also mismatched.

The exhaust system is so over-attached (and it was done with broken en...
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20200313_182311.jpg
133 hits | 108.07 KB | Posted: 3/13/20
It's going back together...
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20200315_164630.jpg
116 hits | 89.48 KB | Posted: 3/15/20
I spent a lot more time than I expected because it took 3 tries to get the setup right. But the frame is tweaked back where it belongs now.
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20200315_205904.jpg
111 hits | 96.29 KB | Posted: 3/15/20
Turns out the battery hold-down had been replaced with a threaded rod with the wrong thread pitch, so I had to unjam it & chase the threads. The tray was also bent, and both battery terminals had to be cleaned & straightened. The positive nut was rou...
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20200315_195057.jpg
233 hits | 112.09 KB | Posted: 3/15/20
I thought the master cylinder reservoir was dark at the bottom because of the shadow of the dark fluid in it. But when it stayed dark after I removed most of the fluid, I realized it was thick sediment. So I pulled the reservoir, wiped most of the gr...
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20200315_205920.jpg
140 hits | 80.82 KB | Posted: 3/15/20
I still have to run the silicone vacuum lines; mount the charcoal canister, and install the plastic reservoir; but the engine is pretty much done. It passed the coolant pressure test, but the PSF needs to be topped-up after the engine runs.
IF THE IM...
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20200317_135350.jpg
894 hits | 83.84 KB | Posted: 3/17/20
After running the silicone vacuum lines, the hood went back on.
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