Rebuild Thread
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Postmaster
Joined: Sep 2016
Posts: 3,941
Likes: 240
From: Texas
UPS was way late delivering the roll of firewall sheet and radiator. I tinkered in the shop until 8:30 and drove out to the gate and waited and he showed up about ten minutes later. I got the firewall covered and installed and had everything ready to roll the engine in by 1:00am. The upgraded Mishimoto radiator is about 7/8” thicker than the other one and the transmission orifices are about three times larger in diameter. I’ll post some comparison photos later.
I had to helicoil two valve cover bolt thread bosses in the rockers. I never went to spec on the torque value the service manual shows at 71 ft/lbs. I think it’s a typo. Anyway, I got the lift plate and lift rigged up and rolled her in place. It took me a little over an hour to stab the transmission but I’m working solo. Needless to say I got my sit-ups in for the week! I took a lunch break to shower and eat then headed back out to continue.
I had to helicoil two valve cover bolt thread bosses in the rockers. I never went to spec on the torque value the service manual shows at 71 ft/lbs. I think it’s a typo. Anyway, I got the lift plate and lift rigged up and rolled her in place. It took me a little over an hour to stab the transmission but I’m working solo. Needless to say I got my sit-ups in for the week! I took a lunch break to shower and eat then headed back out to continue.
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Postmaster
Joined: Sep 2016
Posts: 3,941
Likes: 240
From: Texas
I have to go look at it again, I could have sworn it read ft/lbs. I knew it wasn’t right. These damn valve covers have been on and off so many times I’m surprised they didn’t strip out a year ago.
Hotshot
Joined: Dec 2014
Posts: 17,824
Likes: 3,104
From: Jersey Shore
2003 Ford DVD Service Manual, a pre-production one. It has errors, like they all do, just not that one. I tend to confirm by using two sources, I also have the International one that's on-line, and I think I dropped that into a thread on here at some point.
There's no way that rocker box can handle that torque. I've heard it being stripped out before, there must be a number of those manuals out there that people are following.
There's no way that rocker box can handle that torque. I've heard it being stripped out before, there must be a number of those manuals out there that people are following.
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Postmaster
Joined: Sep 2016
Posts: 3,941
Likes: 240
From: Texas
Mated up without forcing it.
No firewall stud trimming necessary Fuzzpuss...I tightened my v-band clamps with everything lined up while the engine was on the stand so it would line up easy. Installed the y-pipe in one unit.
Turbo to down pipe and collector buttoned up.
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Postmaster
Joined: Sep 2016
Posts: 3,941
Likes: 240
From: Texas
We had family day today and after my son was in bed I had to take some time to knock out the turbo and pipes. I will button the rest up tomorrow and hopefully have her purring tomorrow evening if I don’t fart around with OCD stuff tomorrow...
The trick to any Y-pipe installation, turbo and down pipe is to wire the down pipe up and out of the way, leave up pipe bolts loose at the manifolds, leave turbo to pedestal bolts completely out, leave pedestal to block bolts out and mate up the y-pipe without forcing it, clamp it then work the down pipe so it mates up easily, clamp it then turbo to pedestal bolts then finally the pedestal to block and torque the pipe to manifold bolts last. Do it this way and you won’t have exhaust leaks from trying to use the v-band clamps and pry bars to pull the mating surfaces together.
The trick to any Y-pipe installation, turbo and down pipe is to wire the down pipe up and out of the way, leave up pipe bolts loose at the manifolds, leave turbo to pedestal bolts completely out, leave pedestal to block bolts out and mate up the y-pipe without forcing it, clamp it then work the down pipe so it mates up easily, clamp it then turbo to pedestal bolts then finally the pedestal to block and torque the pipe to manifold bolts last. Do it this way and you won’t have exhaust leaks from trying to use the v-band clamps and pry bars to pull the mating surfaces together.
Cargo Master
Joined: Nov 2015
Posts: 3,420
Likes: 934
From: Fort Worth, TX
Looks like you forgot the intake manifold, or did you upgrade to a late model one without the bridge? Of course I'm speculating that the 05 and up manifold can go in after the turbo is mounted.
