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2002 engine rebuild

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Old 06-21-2014, 06:13 AM   #21
WJL
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Ok whatever you say.
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Old 06-21-2014, 07:27 AM   #22
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Quote:
Originally Posted by Hangwire View Post
I have never heard of Ford having engine block webbing differences between the autos and manuals for 99-04 Mustangs. The only thing that dictates the differences between any of the 99-04 engine blocks was what year and ford plant it was built at(Windsor/Romeo). And even there are minimal differences. Most have to do with the cylinder heads/timing sets and how they attach.
Crankshafts are different too. Windsor is 8 bolt and Romeo is 6 bolt in most cases, IIRC. That also means different flywheel or flex plate for manual/automatic.

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Old 06-22-2014, 05:44 PM   #23
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Default Motor is out

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Old 06-22-2014, 07:13 PM   #24
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Quote:
Originally Posted by JC316 View Post
Oh yeah, that passenger side exhaust always sucks. I always leave that top starter bolt out. Never had a problem. If it were shimmed like the SBC starters, it would be necessary, but I see absolutely no benefit to it being there.
I tried to convince myself that it was ok to leave the top starter bolt out until I got a close look at the bolt bosses on the trans that those bolts go in to.

There's not much meat there and its aluminum at that so I had to put that top bolt back in to be able to sleep at nights.

Getting to these bolts isn't too bad if you using a 24" extension from the front with a universal joint on it, but this was on lift with another pair of hands to get the socket set on the bolt head.
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Old 06-22-2014, 09:02 PM   #25
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Default And now we see why cylinders 3 & 4 weren't firing...

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Old 06-22-2014, 09:04 PM   #26
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There were seven bolts on the passenger side cam retainer bosses that were finger tight or less. The bosses flexed and all four rockers for cylinders 3 & 4 fell out. I thought by the compression test and misfire codes that the lifters had collapsed. Turns out it was even worse than that.
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Old 06-23-2014, 06:56 PM   #27
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I was surprised to see cast iron, ratcheting tensioners when I took the timing cover off:



2002 engine rebuild-forumrunner_20140623_185542.jpg

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Old 06-23-2014, 08:00 PM   #28
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Thin coat of sludge in the oil pan:



2002 engine rebuild-forumrunner_20140623_195643.jpg

Overall, not too bad for 143K miles:



2002 engine rebuild-forumrunner_20140623_195816.jpg



2002 engine rebuild-forumrunner_20140623_195903.jpg



2002 engine rebuild-forumrunner_20140623_200002.jpg

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Old 06-23-2014, 08:13 PM   #29
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2002 engine rebuild-forumrunner_20140623_201258.jpg



2002 engine rebuild-forumrunner_20140623_201308.jpg

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Old 06-24-2014, 01:53 AM   #30
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Hey man I think you might want to have those things connnected haha.

Thats pretty crazy that the bosses would flex. That is completely abnormal wear/defect. I dont think i've ever heard of bosses flexing and rocker/rollers just falling the hell out. Something along the way caused the bizarre behavior with those lifters/rockers/valves.

I wonder if the worn/cracked component started to let the cam run incorrectly. As small as that difference would be.

This is good stuff. Keep doing work!
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