in about a month my friend and i are gonna pull the motor outta my 84 and rebuild it, also we are gonna do a full clutch job on it while everything is unbolted. it needs a new clutch, and there is no point in a new clutch with the rear main dumping oil all over it. with an engine with as many miles as it has i might as well rebuild if i am gonna do a new rear main, new pan seal and new oil pump. i am just wondering if anyone knows of anything i need to watch out for when we do this, anything special i need to know. i plan on new water pump, new o2 sensor, new cap, rotor, new filters. my rebuild kit has the oil pump and timing gears included. i know the flywheel and the head need to go to the mechine shop. i have a torque wrench that goes up to 150 ft/lbs, should i have a bigger one, it's half inch drive clicker type. Other than that i know i have all the tools i need. i am pretty good as a backyard mechanic and my friend went to vo-tech and we have both been present for or have done motor swaps before, however neither of us have done a rebuild, we figured there is only one way to learn and if we screw up there is a good ford junk yard about 10 miles away that can give me a used motor to cover up my goof for about 250 bucks. so what i am really asking is, is there anything i am overlooking, its a 300 i-6 with the manual 4speed od.

 

It's your lucky day. I just did the break in on my 83 300-6 rebuild. I went to Napa to get the parts (they are more knowledgeable in my area) and Autozone to get loaner tools. When I put mine back in I had the PS pump on, but not the alt or fan/clutch assy. It was a squeeze to slide back in. I used my work crane to do it by myself. Be very careful not to damage the pilot brg when recoupling the motor and tranny. If you're going to do it, go through the motor thoroughly to make sure you only do it once. Mine runs, need to tweak the timing for the new perf. cam, but other than that, runs like a champ. If you bore the motor, suggest an elect fan in front of rad (Advance Auto 69 bucks) my temp ran 230 after idling now at 195. Suggest using a Haynes man, and follow/ask questions saves a lot of time. Also, Ford did some swaps between 83-84 (head, r. arms)and 88-89 (oil pan gasket). Make sure you check your parts before the store closes on Sunday. I broke the cam thrust plate on sunday, had to order, took a week, what a drag.
That is all, if you want photos, email me at rocknwhiteboy@atlantic.net