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1987 - 1996 F150 & Larger F-Series Trucks 1987 - 1996 Ford F-150, F-250, F-350 and larger pickups - including the 1997 heavy-duty F250/F350+ trucks

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Old 12-30-2012, 07:24 PM
soco soco is offline
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Cracked bolt hole behind timing cover

Previous owner did some work and now I'm feeling the repercussions. I changed out the water pump and I accidentally cracked the timing chain cover. After we got that off, we found that a bolt had been broke off in the block, drilled/tapped, and at some point the ear of the hole had cracked too. Now I need to reinstall the timing cover but one of the holes doesn't have anything for the threads to catch.

This is on a 1995 F150 with a 302. I'm open to suggestions/ideas.

View image: photo (2)

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It's the lower left bolt hole that is broken (in the bottom of the "Y" in the photo).
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Old 12-30-2012, 07:33 PM
bakos bakos is offline
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Are you saying a chunk of the block is broke off?
Might need a machinist to fix. Without seeing it if it were me I'd weld a nut on the block - fill missing area with welder - grind it down flat smooth to make a sealing surface. No real pressure or precision mechanics happening on a timing cover
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Old 12-30-2012, 07:55 PM
soco soco is offline
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Edit: added photo to the top post
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Old 12-30-2012, 08:03 PM
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92 Black Nite 92 Black Nite is offline
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I had the upper bolt hole problem . I used a cobalt drill bit and drilled into the water jacket in the block. Tapped a 5/16-18 thread and used 5/16-18 threaded rod washers and nuts w/sealant. It has been on my engine for 5 years . This is not an easy fix. The drilled & tapped the hole must be straight or it will not go through the cover and water pump. I have saved some blocks and Harley Davidson engine cases over the years. As Bakos said, You Might need a machinist to fix it ,if your not sure you can do it get someone that has experiance
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Old 12-30-2012, 08:17 PM
soco soco is offline
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Quote:
Originally Posted by 92 Black Nite View Post
Are talking about the bolt hole on the right upper side that goes through the water pump/timing cover then into block just below the cyl. head ??
Please post photo so I can see if you have the same issue I had
Yes, it's on the right hand side but it's the lower/inner bolt, not the upper side. This bolt does go through the water pump and timing cover as well.
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Old 12-30-2012, 09:00 PM
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92 Black Nite 92 Black Nite is offline
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Yes, I saw that. As I said ,this is not easy. I start with a small pilot hole and make sure the hole is straight as I go up to the final drill/tap size. You have a tough one here guy. The ear of the bolt hole is broken off and it is best left to someone who has done similar issues before. Even, I would tell you I would do my best to save your block, But with this problem there's no guarantee
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Old 12-30-2012, 11:12 PM
bakos bakos is offline
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Tack weld a stud onto the block - put cover on and make sure it's straight - then tack some more - put cover on and make sure it's straight - then weld it - make sure all welding is inside and lower then mounting surface. Once again seems like ultra precision and super strength is not critical factor

Just a thought - if it sounds hokey just disregard
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Old 01-03-2013, 03:19 PM
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92 Black Nite 92 Black Nite is offline
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soco, Have you fixed your block or how are you making out ?
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Old 01-03-2013, 03:19 PM
 
 
 
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