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#3308074 - 03/11/14 08:36 AM One of the most hateful repairs I've ever done
chestand Offline


Registered: 09/20/11
Posts: 169
Loc: Kansas City
1997 Thunderbird - 4.6 Modular

I've read that the 4.6 SOHC is a great motor. I'm sure it is, but given enough time, they all seem to develop an oil leak around the oil filter adapter. It's a casting on the driver's side of the engine block down low in the front. The gasket is a composite with the orange sealing rings built into it. The gasket seals the oil filter input/output and the lower radiator hose output. In time, the rings sealing the oil passages crush down flat and oil leaks around the adapter. Because of the way the engine is mounted in the T-bird, there is virtually no room to access the bolts that hold the adapter on. Even getting to the oil filter is a PITA. The engine was leaking a quart of oil every two days, so it had to be done. I had to go through the wheel well sway bar opening with 20 inches worth of extensions, a ujoint and a 10mm socket. Took a total of 5 hours start to finish. Not one of Ford's better ideas.

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#3308089 - 03/11/14 08:52 AM Re: One of the most hateful repairs I've ever done [Re: chestand]
Chris142 Offline


Registered: 06/05/03
Posts: 14848
Loc: apple valley, ca
Nice. Imo ford likes to make simple things miserable. It started with the lower thermostat housing bolt behind the timing cover on the 260,289,302
_________________________
02 Wrangler super-s 10w30
87 F250 proline 15w40
04 Tahoe super-s 5w30
Z400 Lucas 10w30
KLR250 Maxima 10w40
Can am maveric edge 5w40

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#3308101 - 03/11/14 09:05 AM Re: One of the most hateful repairs I've ever done [Re: chestand]
Donald Offline


Registered: 03/21/04
Posts: 18201
Loc: Upstate NY
I think the fuel pump on my Suburban was the worst for me. Lots of road dirt dropping on your face as you try and free up the fuel tank. Its heavy even when empty. Steel fuel lines that snap vs unscrewing. A bunch of waxy goo to remove that keeps the access plate clean.

Doing it the second time was easier but more annoying at having to do it a 2nd time in a year.
_________________________
2015 Subaru Forester 2.5 engine/CVT
2015 Ford F250 w/Powerstroke
2016 Subaru Crosstrek CVT (wife's)


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#3308103 - 03/11/14 09:06 AM Re: One of the most hateful repairs I've ever done [Re: chestand]
zzyzzx Offline


Registered: 05/18/12
Posts: 3796
Loc: Baltimore, Maryland, USA
Who was making you get the V8 when you could have gotten the smaller V6?

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#3308125 - 03/11/14 09:37 AM Re: One of the most hateful repairs I've ever done [Re: zzyzzx]
chestand Offline


Registered: 09/20/11
Posts: 169
Loc: Kansas City
Originally Posted By: zzyzzx
Who was making you get the V8 when you could have gotten the smaller V6?
I bought the car used. I took the engine that came in it....

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#3308165 - 03/11/14 10:30 AM Re: One of the most hateful repairs I've ever done [Re: chestand]
jeepman3071 Offline


Registered: 04/15/10
Posts: 2659
Loc: Storrs, Connecticut
Those can be a pain. I had the same thing happen on my Jeep. The oil filter adapter was leaking a ton of oil. Luckily, the Jeep is easy to work on. I could see the adapter when I opened the hood, but I still needed a breaker bar to break the bolt free. I can only imagine how hard of a job that is with limited room.
_________________________
2000 Jeep Cherokee Sport 4.0L (172k) - PYB 5w30, Wix 51516, Magnefine trans filter

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#3308168 - 03/11/14 10:35 AM Re: One of the most hateful repairs I've ever done [Re: zzyzzx]
Colt45ws Offline


Registered: 08/15/06
Posts: 8989
Loc: Central Washington
Originally Posted By: zzyzzx
Who was making you get the V8 when you could have gotten the smaller V6?

Yes, get the 3.8L so you can feed it head gaskets.

A gasket went bad on a 17 year old engine with an unspecified number of miles. I guess its a bad engine.[/sarcasm]
_________________________
-Colton
2002 Ford Crown Vic PI, 198k "Highwayman"
Ex-Kootenai County, ID Unit #42
Maxlife 5W20
Lubegard Bio/Tech oil treatment
Ultra XG2

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#3308188 - 03/11/14 11:03 AM Re: One of the most hateful repairs I've ever done [Re: chestand]
ag_ghost Offline


Registered: 12/08/10
Posts: 585
Loc: SF Bay Area, CA
Every car has some bits that are a PITA to service, including Fords. How about a timing chain on a 2001 Ecotec motor? Fuel filter on a 2000 Mazda 626? The list goes on.
In any event, congrats on getting it done.
Kevin
_________________________
66 Mustang (289)-Valvoline VR1 10W30
63 Galaxie 500 (390)-Chevron 10W40
99 Accord V6-Chevron 5W30
15 CR-V M1 EP 0W20

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#3308191 - 03/11/14 11:07 AM Re: One of the most hateful repairs I've ever done [Re: ag_ghost]
chestand Offline


Registered: 09/20/11
Posts: 169
Loc: Kansas City
Originally Posted By: ag_ghost
Every car has some bits that are a PITA to service, including Fords. How about a timing chain on a 2001 Ecotec motor? Fuel filter on a 2000 Mazda 626? The list goes on.
In any event, congrats on getting it done.
Kevin

Thanks. As time goes on, you tend to forget repair based PITA's. I recall my brother's Saab 9-5 was never easy to do anything under the hood. At least I haven't had any of the Ford spark plugs launching out of the head to deal with yet.

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#3308214 - 03/11/14 11:36 AM Re: One of the most hateful repairs I've ever done [Re: chestand]
Clevy Offline


Registered: 11/11/10
Posts: 9783
Loc: Saskatoon canada
New threads in a 2v that spit a plug,especially when tight to the firewall. I had to take the hood off to thread the insert straight.
_________________________
2006 Charger RT
Miles x 2 per oil filter

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#3308218 - 03/11/14 11:38 AM Re: One of the most hateful repairs I've ever done [Re: chestand]
Darwin1138 Offline


Registered: 01/07/14
Posts: 393
Loc: Slimy Mudhole
If you think Ford engineering is crazy wait until you work in a Renault Clio/Megane when every repair procedure starts with:

1. Lift the car in a two post hoist
2. Remove front wheels
3. Remove front mudguards
4. Remove front bumper
5. Remove front headlamps
6. Remove radiator support.
7. Support the engine and remove engine mounts.
_________________________
0W-20 or death!

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#3308234 - 03/11/14 11:58 AM Re: One of the most hateful repairs I've ever done [Re: chestand]
A_Harman Offline


Registered: 10/01/10
Posts: 6260
Loc: Michigan
I just replaced the power steering pump on my Camaro last week. It's up high on the front of the engine, but the two bolts that attach it to the cylinder head can only be accessed with an open end wrench, and you can only turn the bolts a half-flat at a time. Oh yes, the ABS module has to be dismounted and moved aside to get any access to the outboard bolt. All told, I was wrenching on those two bolts for about an hour to get them out.

Then I broke the phenolic pulley trying to get it off the pump and had to buy a new one. Then I tried to get smart, and had a local machine shop drill access holes in the new pulley so I could use a socket to run in the bolts. The access holes worked like a charm, and it only took me about 5 minutes to install the new pump. But now I'm worried about durability of my new phenolic pulley because the access holes are chipped at the corners and may cause the web to crack over time.

Some jobs just go wrong from the start.
_________________________
1985 Z51 Corvette track car
2002 Camaro Z28 LS1/6-speed
2001 Dodge Ram 2500 diesel
1972 GMC 1500 shortbed project truck

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#3308240 - 03/11/14 12:07 PM Re: One of the most hateful repairs I've ever done [Re: A_Harman]
ls1mike Offline


Registered: 06/14/08
Posts: 4532
Loc: In the Garage...
Originally Posted By: A_Harman
I just replaced the power steering pump on my Camaro last week. It's up high on the front of the engine, but the two bolts that attach it to the cylinder head can only be accessed with an open end wrench, and you can only turn the bolts a half-flat at a time. Oh yes, the ABS module has to be dismounted and moved aside to get any access to the outboard bolt. All told, I was wrenching on those two bolts for about an hour to get them out.

Then I broke the phenolic pulley trying to get it off the pump and had to buy a new one. Then I tried to get smart, and had a local machine shop drill access holes in the new pulley so I could use a socket to run in the bolts. The access holes worked like a charm, and it only took me about 5 minutes to install the new pump. But now I'm worried about durability of my new phenolic pulley because the access holes are chipped at the corners and may cause the web to crack over time.

Some jobs just go wrong from the start.

You are doing it wrong... cheers
Pull the pulley than go at. I have done the one in the Trans Am 45 minutes out and in. Never touched the ABS module.
_________________________
Mike
00 Trans Am WS6 5.7 LS1
02 Silverado 2500HD 6.0
14 Caprice PPV 6.0
15 Malibu LTZ Turbo
12 Passport TT

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#3308339 - 03/11/14 02:04 PM Re: One of the most hateful repairs I've ever done [Re: chestand]
Vikas Offline


Registered: 07/22/05
Posts: 10913
Loc: NorthEast
Quote:
I had to go through the wheel well sway bar opening with 20 inches worth of extensions, a ujoint and a 10mm socket. Took a total of 5 hours start to finish.
I do not know this engine but I don't quite understand why one implies other! I am assuming there can be no more than 3 bolts holding the thing you wanted to replace. Please explain the 5 hours.

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#3308386 - 03/11/14 03:01 PM Re: One of the most hateful repairs I've ever done [Re: ls1mike]
A_Harman Offline


Registered: 10/01/10
Posts: 6260
Loc: Michigan
Originally Posted By: ls1mike
Originally Posted By: A_Harman
I just replaced the power steering pump on my Camaro last week. It's up high on the front of the engine, but the two bolts that attach it to the cylinder head can only be accessed with an open end wrench, and you can only turn the bolts a half-flat at a time. Oh yes, the ABS module has to be dismounted and moved aside to get any access to the outboard bolt. All told, I was wrenching on those two bolts for about an hour to get them out.

Then I broke the phenolic pulley trying to get it off the pump and had to buy a new one. Then I tried to get smart, and had a local machine shop drill access holes in the new pulley so I could use a socket to run in the bolts. The access holes worked like a charm, and it only took me about 5 minutes to install the new pump. But now I'm worried about durability of my new phenolic pulley because the access holes are chipped at the corners and may cause the web to crack over time.

Some jobs just go wrong from the start.

You are doing it wrong... cheers
Pull the pulley than go at. I have done the one in the Trans Am 45 minutes out and in. Never touched the ABS module.


How did you get the pulley off? It didn't look like there was enough room to install a puller with the pump in the car.
_________________________
1985 Z51 Corvette track car
2002 Camaro Z28 LS1/6-speed
2001 Dodge Ram 2500 diesel
1972 GMC 1500 shortbed project truck

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