Started working on the 4.6 removal on Monday. I've got the intake, fan, alt off. Working on dropping PS,AC,starter.

Looking for advice/hints. One problem is this engine is locked up. Don't know if I'll be able to rotate it to loosen converter. Hoping if it dosent turn I can remove it after seperation from trans or pull it out with converter on?

Also read about using feet of extensions to get engine to trans bolts? Any hints in this area.


2003 F150 extra cab 4X4 FX4

 

I will have to applaud who ever works on these things for a living! I'm a mechanical technician for a living. I've build a few hot rods. I maintain all my cars. From a engineering point of view its not too bad. Sure putting this thing together on the line was probably easy. Maybe a dealer would take the cab off. So many things in the design are not owner DIY guy friendly.

How the hell do you even get the exhaust off the manifold. The pipe comes out a few inches and then turns down right in the way. Passenger side.

 

I use a 4 foot extension and a wobbly socket to get the bell housing bolts loose. I work from back near the transmission tail shaft with an impact wrench. The wobbly sockets are a ball and socket design that gives pretty smooth range of motion.
I don't remember on the 2003 pickups, but I know the expeditions around that year required the body to be lifted off the frame. I had the advantage of using a lift on the last one I did, but I found it helps to pull the wheels off the front end. You can set it down lower to get to work up top, then lift it to get under it.
For the exhaust bolts I also used a long extension and an impact with the wobbly sockets. I have even found it easier on the passenger side to pull the inner fender wells out. The plastic inside of the fenders come off fairly easy, then you can reach into the exhaust. They still have to be wrenched from underneath, but you can reach in to get the sockets on the bolts.
Yes, I think you can pull the torque converter off with the engine as long as you pull enough off the front to get enough room. You will have to pull the engine straight ahead from the transmission a few feet to get it loosened. One option you might have is to pull the heads off, then see if you can get the oil pan off to et the engine to turn.
I have heard that when they design airplanes the engineers have a fake hand on a fake arm. If they can not get the hand and arm into a tight spot to do maintenance, they change the design. They don't want things to be so complicated and hard to work on that the maintenance mechanics skip steps.

 

If does that, it must be something other than a human arm.