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ED Head Gasket Replacement 

 

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 Post subject: ED Head Gasket Replacement
Posted: Mon Feb 16, 2009 1:38 pm 
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Ok, this is probably going to be the stupidest question ever, until waggin gets the Search Function up and running again but.

Bear with me, I have never pulled the rocker cover off my own ED or any other Ford! I have only done Head Gasket Replacement to a VN Commonbore.

Is it possible to remove the head without removing the Cam Gear????

So far I have done:

Undone Bolts to Extractor's, and removed it's Gasket
Undone Bolts to Inlet Manifold, and removed it's Gasket
Removed Rocker Cover.

Looking through some of the stuff on the forums I will need to:

Remove Power Steering Pump
Cable Tie Cam Sprocket to Timing Chain

Anything else I should be doing?


:? :? :? :? :? :? :?

 

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 Post subject: Re: ED Head Gasket Replacement
Posted: Mon Feb 16, 2009 2:45 pm 
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thought I would take some photo's of what I have:

 

 

Attachments:
Cam Gear 004.jpg
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Cam Gear 003.jpg
Cam Gear 003.jpg [ 134.8 KiB | Viewed 113 times ]
Cam Gear 002.jpg
Cam Gear 002.jpg [ 129.28 KiB | Viewed 117 times ]
Cam Gear 001.jpg
Cam Gear 001.jpg [ 125.65 KiB | Viewed 140 times ]

 

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 Post subject: Re: ED Head Gasket Replacement
Posted: Mon Feb 16, 2009 3:02 pm 
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Remove rocker gear and cam, be sure not to lose lifters down into the sump.

Loosen the timing chain at the tensioner.
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 Post subject: Re: ED Head Gasket Replacement
Posted: Mon Feb 16, 2009 3:05 pm 
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I'm having to resort to Boostedfalcon.net for a detailed guide on what to do, there are a few more easy steps that I can do, which is take off the power Steering Pump, a few belts, and Turn the Crankshaft Clockwise to TDC.

Once I have done that then what I think is the tendious bit begins, which is to remove the Camshaft and rocker Gear......

And it's annoying too because the guide on Boosted Falcon.net doesn't show pics :x......

 

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 Post subject: Re: ED Head Gasket Replacement
Posted: Mon Feb 16, 2009 4:55 pm 
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ok, I have taken off the Power Steering Pump, I have set the Crankshaft to TDC.

I have taken out the Filler Plug, that big bolt thingy on the side of the head, along with this other weird looking thing, which I got out with a coat hanger.

Now my problem is trying to release the tension, I can't figure out how to possibly do it...

On the boosted instructions you are technically supposed to use a Ford Special Tool to release the tension, but it says that using a 3mm allen Key, with a tube hanging over by 5mm, but how big a diamater tube am I supposed to use??? because I can't see how it can be released :? :? :?

 

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 Post subject: Re: ED Head Gasket Replacement
Posted: Mon Feb 16, 2009 5:07 pm 
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damn the lack of search function !!!

i started a thread awhile ago asking about the tensioner and alot of good info for 'beginners' is in there.

bascially the tensioner has an outside bit with slanted teeth cut into it, and a dowel pin which locks its way up & down to adjust the tension. Outside tube pushes the cylinder together, whilst the allen key in the middle turns the dowel through the teeth to the shut position

Stick your head around the side with a flashlight, you will see you need the largest hollow tube that will fit in there. And cut it short enough so that the allen key is exposed enough to reach the slot. Push and turn clockwise till it locks together, this will loosen the chain
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 Post subject: Re: ED Head Gasket Replacement
Posted: Mon Feb 16, 2009 5:37 pm 
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fordmods-technical-documents-diy-f38/head-gasket-doco-started-t22726.html

Read this...it will help you through it.

I'm in the process of making a Tech Doco of this...but it has taken me AGES to even put it together being lazy and lacking Office on this computer.

phong =P~

 

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 Post subject: Re: ED Head Gasket Replacement
Posted: Mon Feb 16, 2009 6:08 pm 
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yeah the thread phong listed shows all the details, do what it said.

some things youll need.
-14mm IMPACT socket
-GOOD breaker bar, you saw the one i bent at AFD
-zip ties for the timing chain to the vernier gear.
-undo the bolt in the right hand side of the head dont forget it or snapped timing guide will result, (not deadly just rattly at low rpm).

tbh removing the rocker gear is easy, its cleaning the block REALLY WELL, and the reall tediuos pain is putting the rocker gear back on (try to keep your lifters in when removing (use tape) so you dont have to redo them.

hope it helps.
Rushed

 

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 Post subject: Re: ED Head Gasket Replacement
Posted: Tue Feb 17, 2009 1:08 pm 
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Well know I see what I'm trying to turn, but with the correct diameter Hollow Tubing and allen Key that hangs out by 5mm as suggested by the boosted guide aint working... and I've been trying to turn it clockwise for the last 2 hrs... turning the top most end of that dowel thingo towards the front of the car, if you can picture what I mean....

It feels much easier to get a set of plyers and twist the darned thing... but no they don't fit :x.

 

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 Post subject: Re: ED Head Gasket Replacement
Posted: Tue Feb 17, 2009 5:38 pm 
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Well, I after about 5 hr's I finally managed to release the tension on the timing chain, but I ended up making this to do it:

Attachment:
Timing Chain Tension Release Tool 001.jpg
Timing Chain Tension Release Tool 001.jpg [ 164.42 KiB | Viewed 107 times ]
Attachment:
Timing Chain Tension Release Tool 002.jpg
Timing Chain Tension Release Tool 002.jpg [ 107.59 KiB | Viewed 98 times ]
Attachment:
Timing Chain Tension Release Tool 003.jpg
Timing Chain Tension Release Tool 003.jpg [ 108.87 KiB | Viewed 76 times ]


With abit of force from this tool I managed to release the tension, but there was enough tension on it that not even the "allen key" trick would have been able to release, because it was too tight to be done with an Allen Key...

 

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 Post subject: Re: ED Head Gasket Replacement
Posted: Tue Feb 17, 2009 10:27 pm 
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Well I have hit another snag.

I've rounded one of the bolts that connect to the head :(.

I was even using the impact wrench.....

So I guess I will make a start to filing the edges back tomorrow and go from there (p.s, I was using a six point socket).

 

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 Post subject: Re: ED Head Gasket Replacement
Posted: Tue Feb 17, 2009 11:14 pm 
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SpeedyED wrote:
Well I have hit another snag.

I've rounded one of the bolts that connect to the head :(.

I was even using the impact wrench.....

So I guess I will make a start to filing the edges back tomorrow and go from there (p.s, I was using a six point socket).


...6 sided impact socket rounded the head? Either you bought a one size too large socket, or the socket is cheap.

I managed to remove the bolts with a good set of hex socket set...and tighten them with a hex without problems :?

Make sure the socket is noice and toight on the bolts before you attempt to undo them...and also make the socket is STRAIGHT on top of the bolt, not on an angle.

Use a T-Bar with an extension...I had a 1.5m steel tube that fit over one end of the T-bar to remove my bolts and tighten them.

phong =P~

 

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 Post subject: Re: ED Head Gasket Replacement
Posted: Wed Feb 18, 2009 12:42 pm 
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well this is now seriously giving me the s**t this head bolt, I've just spent all morning fileing the stupid f**k thing and I go to use the impact wrench yet again, it was still a tight fit but yet again it failed me and rounded for the SECOND time :x :x :x..... and I'm even using quality SNAP-ON impact sockets.... what the f**k am I supposed to do now????

 

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 Post subject: Re: ED Head Gasket Replacement
Posted: Wed Feb 18, 2009 1:23 pm 
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If possible, hit the head of the bolt, hard, then try undoing it.

 

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 Post subject: Re: ED Head Gasket Replacement
Posted: Wed Feb 18, 2009 1:26 pm 
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well atm I'm supposed to actually be at an appointment atm, I'm still fairly annoyed/upset that the quality SNAP-ON sockets and impact failed twice in a row, never the less I might give the bolt a wack or 10.

From there if I do succeed in getting the bolt out I will then proceed to venting my feelings on it :lol:

 

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