1996 bronco 5.8. E4 OD

I needed to pull the engine for a leaky rear main seal and broken exhaust manifold bolts. I haven't pulled an engine since 1990 and I have never pulled an engine on a Ford, so It was a learning moment. Here are my takeaways from the experience.
1. If you can, take it to a car wash and clean the engine compartment as best as you can. that would have saved me lots of time cleaning parts.
2. take lots of pics before you start. Working on a Ford is new to me and my elderly brain isn't as good as it once was. The pics helped immensely for reassembly.
3. I removed the passenger side inner fender wheel well to see my broken exhaust manifold bolts. When I decided to pull the engine I felt having it out of the way was a great help for getting to the tranny bolts, and it wasn't hard or very time consuming.
4. I used 2 chains for lifting the engine and there must be an easier way. I bought a load leveler but couldn't use it. I wouldn't have had enough lift height with my shop crane to clear the radiator support. It might have worked if I pulled the intake plenum but I was trying to avoid that.
5. I tried to install my engine with the motor mounts attached to the motor and that didn't work for me. Once I removed them it was much simpler to line up the tranny and engine. For whatever reason ( possibly the way I was lifting the engine with the chains) the engine was slightly twisted, I could get the passenger side to mate up but the drivers side was a bit off. I used a long bolt I had bought to put my engine on the engine stand to pull the engine and tranny together on the drivers side, and it worked great.

Anyhow I hope this will help someone else doing an engine R and R. Good Luck!

nyhow I hope this will help someone else doing an engine R and R. good luck!

 

Good advice is always helpful
Most of us pros will at least remove the upper intake
That means you can use a shorter chain and lessen the risk of crashing the cherry picker
Good job

 

Yes I think in hindsight I should have removed the Upper intake. It would have made the job easier. I was nervous about getting in over my head and the Bronco never running again. After all the work I did I feel much more comfortable working on it, the unknown is what makes me doubt my ability. Some things Ford did is easier than GM . Thanks for calling it a Cherry Picker! that is what I always called it growing up but thought the term was outdated.

 

I always use a really long ratchet extension to get at the bell housing bolts.... I can stand behind the transfer case and turn them. Makes life a lot easier.
When removing the upper plenum, make sure you have the right torx driver for the mid, inner bolt. Only one that is different.
I was able to get my engine to clear the core support by removing the tires up front. The motor mounts were installed.

 

In case you weren't told, the center bolt on upper intake on passenger side is a Torx bit T40, and the rest are hex heads, my uncle reverted to taking the front wheels(35") off his and lowered it down to get engine out, in his garage.

 

I use a 3 foot long Snap-On extension that is 1/2 drive but holds a 3/8 drive socket, and a 3/8 drive, 5/8 impact wobbly socket.
Reason
I started out on the line as a trans R&R guy
The AOD's had just came out and none had 4th gear for long
Especially in cop car Crown Vic interceptors back then
Did 2 a week for weeks, years maybe
Do you know the term "torque converter rattle" 96broncofan?
You need to make that torque converter "rattle" during the install

 

Is that the noise of the free movement of the torque converter before you tighten the bolts? my torque converter was loose and would rattle in the holes.

 

I considered taking the wheels off but I didn't have to. thanks for the info on the right T40 bit.

 

Stephen.osborne1, good to know about the motor mounts. I just wasn't able to get the motor to go back far enough to drop the motor mount studs in the frame holes. I finally got tired of getting up and down. I was working alone. What part of Montana are you from? I'm In Missoula.

 

Yes, good job. you are ready now
That is the cardinal rule of engine or trans R&R with an automatic