Just drove it. She works!

Hasn't this been a fun and interesting thread?

 

Interesting yes...

Fun? No way in heck!

It would be more interesting to see if we can figure out what happened - backfire?

 

Man, I haven't a clue. This isn't my truck, and the guy who owns it isn't a "car guy" so he doesn't know what sounds are what even if I asked him. Could a backfire cause a hole like this? What about somebody sticking something in there for leverage working on pulleys or tensioners?

 

Could be... someone trying to lever on the belt over the alternator pulley? Nah... there's not enough slack in the belt to do that.

Very strange.

 

Good find, my pressure switch post showed up after the picture
I couldn't see it in the first picture, but it has definitely been hit by something.

 

I had the same problem and through the parts at it. I replaced IAC that didn't fix it, and then found out that one of the guys I work with is a retired master tech for ford. He sujested replaceing the crank shaft sensor. That when the plastic houseing cracks with age, and the leads on the magnet dont work. I live in the south east, and never once had an issue in the morning, but in the hot and humid afternoon it never failed-- engine would start then die. Try it again then hold your foot on the gas till the engine heated up enough to displace the mosture in the sensor, then she ran like a champ till she cooled back down again. Have not had a single problem since I replaced it. The least little hickup and my would have left me, since the Expo left her stranded three times!