Hello
Sorry if I missed something here. I'm doing my first e series engine swap on my 92 e250 5.8 e4od. Got everything apart but the core support and fenders. I can't find any repair info. Looks like ill have to remove intake plenum but how do I clear the core /rad. support. It looks welded to the body. Do I have to remove the fenders first. Any help would be greatly appreciated.

 

It should unbolt without difficulty. Its possible your vehicle was in an accident and a new core support was welded in to repair damage.

 

That's what I've read but can't find anything 92 specific. It really looks factory. It looks professionally spot welded to the inner fenders which spot weld to the body. The support has the two front body mounts going through it and I can't find any evidence of damage at all.

 

I don't see where it would come apart. Ford said it should unbolt. Why would someone have gone through all the trouble of tearing the whole front end apart weld the whole front end together and paint it when they could have just bolted it together. That's assuming it was wrecked.

 

The whole front comes off...do NOT touch the fenders only where the bottom valance bolts to the fenders on either side .......You might have to remove the bumper too...I know for my 7.3 I have to ......on your 5.8 (I don't know) ..The engine comes out like a sliding drawer....Maybe the PO did weld it together..there are alot of Bushwacker mechanics out there..who are that stupid and can't read a manual.....

 

OK got it. For anyone replacing their engine in the future. My van is a 92 e250 extended van. I'm not sure what other years this applies to but someone is sure to run into this problem again. The core support can not be removed. It is factory welded along with the inner fenders to the body. I had a former ford factory assembly line worked confirm the welds were factory (dent welds I believe he called them). My brother was able to track down revised repair info that said nothing of removing the core support but to instead remove upper intake plenum and distributor. Take that ford!

 

Ok, I've changed many engines in these vans and it is tight but everthing un bolts. The core support is welded but it is a 3 piece design and the center section un bolts. On your 92 you have the remove the plastic head light/ grille support, the valance pan, the bumper and the center of the core support. (the bolts are about 12'' in from either fender and the hood latch is in the center of this removable section) Also you can remove the engine without removing the plentum a couple different ways, you can take the engine mounts off the frame and engine and slide your engine crane right in beside the plentum attaching it as tight to the engine as possible and as you roll the engine out you will need to lower the front while at the same time raising the rear. If you have a buddy willing to help, one inside one out it comes out pretty easy. Another way I sometimes do it is to remove the mounts from the frame but leave the mounts on the the engine and slide 2 pipes from the lower core support to the trans cross member one under each mount between the mount and oil pan kind of like sled runners, then you can use a come along or even another vehicle to slide it out. Having a helper inside to watch for anything hanging up is a big help. I've used the pipe method on Fords and Chevy's carbed and injected and honestly like this way better than the crane. I can't post pics on here from my phone but if you need to see a 92 with everything removed send me your cell and I will text you pics of a 92 I just yanked the engine out of.

 

As far as I can tell nothing else will unbolt unless as suggested the front clip comes off. That would mean unbolting the front body mounts. The rest of the core support is definitely welded to the inner fenders which is welded to the firewall. I believe this is a unibody. I could be wrong. The plenum gave me a lot of room and was only 6 bolts. Sorry if these pics are no good my screen is damaged so I can't see the pics well. I'm going to pull the engine this afternoon ill let you know how it goes.

 

Here's a couple of pics of the engine coming out over the core support. Removing the upper intake/ intake plenum really seemed to help. I had clearace issues even with the plenum removed using a shop crane and a chain. I ended up flipping the boom upside down to grip a ratchet strap and slid the boom over the lower intake and under the strap. I than ratcheted the strap to take up any slack. That gave me plenty of room to lift the engine.





Also here is the revised repair info for the 92 e250: