CAUTION: Handle the crankshaft with care to avoid possible fracture or damage to the finished surfaces.
Carefully lift the crankshaft out of the cylinder block (6010) so that the thrust bearing surfaces are not damaged.
Section 03-01B: Engine, 5.0L and 5.8L MFI | 1996 F-150, F-250, F-350 and Bronco Vehicles Equipped with 5.0L or 5.8L MFI Engines Workshop Manual |
| Description | Tool Number |
|---|---|
| Spark Plug Wire Remover | T74P-6666-A |
| Clutch Housing Alignment Tool | T75P-6392-A |
Removal
With the engine (6007) removed from the vehicle and placed in a workstand, disconnect the distributor to spark plug wires (12286) at the spark plugs (12405) and remove the wires and bracket assembly from the attaching stud on the valve covers (6582) using Spark Plug Wire Remover T74P-6666-A. Disconnect the ignition coil to distributor high tension wiring (12298) at the ignition coil (12029). Remove the distributor cap (12106) and distributor to spark plug wires as an assembly. Remove the spark plugs to allow easy rotation of the crankshaft (6303).
Drain the crankcase.
Remove the oil filter. Slide the water pump bypass hose clamp toward the water pump (8501). Remove the generator (GEN) (10300) and mounting brackets.
Remove the crankshaft pulley (6312) from the crankshaft vibration damper/pulse ring. Remove the capscrew and washer from the end of the crankshaft. Install Gear and Pulley Puller D80L-522-A or equivalent on the crankshaft vibration damper/pulse ring and remove the crankshaft vibration damper/pulse ring.
Remove the engine front cover (6019) and water pump as an assembly.
Check the timing chain deflection. Then, remove the timing chain/belt (6268) and sprockets. Refer to Timing Chains and Sprockets in the In-Vehicle Service portion of this section.
Invert the engine on the workstand. Remove the clutch pressure plate (7563) and clutch disc (7550) (manual shift transmission). Remove the flywheel (6375) and engine rear plate (7007). Remove the oil pan (6675) and gasket. Remove the oil pump (6600).
NOTE: Make sure all bearing caps (main and connecting rod) are marked so that they can be installed in their original locations.
Turn the crankshaft until the connecting rod from which the cap is being removed is down, and remove the bearing cap. Push the connecting rod and piston assembly up into the cylinder. Repeat this procedure until all the connecting rod bearing caps are removed.
Remove the main bearing caps.
CAUTION: Handle the crankshaft with care to avoid possible fracture or damage to the finished surfaces.
Carefully lift the crankshaft out of the cylinder block (6010) so that the thrust bearing surfaces are not damaged.
Remove rear journal oil seal from the crankshaft.
Remove the main bearing inserts from the cylinder block and bearing caps.
Remove the connecting rod bearing (6211) from the connecting rods and caps.
To refinish journals and dress minor imperfections, refer to Section 03-00.
Installation
If the crankshaft main bearing journals have been refinished to a definite undersize, install the correct undersize crankshaft main bearings (6333).
CAUTION: Be sure the bearing inserts and bearing bores are clean. Foreign material under the inserts will distort the crankshaft main bearing and cause a failure.
Place the upper crankshaft main bearing inserts in position in bores with the tang fitting in the slot provided.
Install the lower crankshaft main bearing inserts in the bearing caps.
NOTE: Be careful not to damage the bearing surfaces.
Carefully lower the crankshaft into place.
Check the clearance of each crankshaft main bearing. Refer to Section 03-00.
Apply engine oil of the quality recommended in the Owner Guide to the journals and crankshaft main bearings.
NOTE: Apply Black Silicone Rubber F4AZ-19562-B or equivalent meeting Ford specifications WSE-M4G323-A1 and ESE-M4G195-A in a 1.59mm (1/16-inch) bead in each corner of rear main bearing cap saddle, the full length of the saddle.
NOTE: Be sure that the main bearing caps are installed in their original locations.
Install all the crankshaft main bearing caps, except the thrust bearing cap (No. 3 bearing). Tighten the bearing cap bolts on 5.0L engines to 82-95 Nm (60-70 lb-ft); on 5.8L SFI engines to 129-142 Nm (95-105 lb-ft).
Install the thrust bearing cap with the bolts finger-tight.
Pry the crankshaft forward against the thrust surface on the upper half of the crankshaft main bearing.
Hold the crankshaft forward and pry the thrust bearing cap to the rear. This will align the thrust surfaces of both halves of the crankshaft thrust main bearing (6337).
Retain the forward pressure on the crankshaft. Tighten the cap bolts on 5.0L engines to 82-95 Nm (60-70 lb-ft); on 5.8L engines to 129-142 Nm (95-105 lb-ft).
Force the crankshaft toward the rear of the engine.
Check the crankshaft end play. Refer to Section 03-00.
Install new bearing inserts in the connecting rods and caps. Check the clearance of each bearing. Refer to Section 03-00.
Apply a light coat of recommended quality engine oil to the journals and connecting rod bearings after the connecting rod bearings have been fitted.
Turn the crankshaft throw to the bottom of its stroke. Push the piston (6108) all the way down until the connecting rod bearing seats on the crankshaft journal.
Install the connecting rod cap. Tighten the nuts on 5.0L engines to 26-33 Nm (19-24 lb-ft); on 5.8L to 54-61 Nm (40-45 lb-ft).
Using a feeler gauge to check the side clearance between the connecting rods on each connecting rod crankshaft journal after the piston and connecting rod assemblies have been installed. Refer to Specifications at the end of this section.
Install a new crankshaft rear oil seal (6701).
Install the timing chain/belt, the sprockets, engine front cover, crankshaft vibration damper/pulse ring and crankshaft pulley.
Coat the threads of the flywheel attaching bolts with oil-resistant Threadlock and Sealer E0AZ-19554-AA or equivalent meeting Ford specification WSK-M2G315-A5. Position the flywheel on the crankshaft flange. Install and tighten the bolts to 102-115 Nm (75-85 lb-ft).
On a flywheel for manual shift transmission (7003), use Clutch Housing Alignment Tool T75L-6392-A to locate the clutch disc. Install the clutch pressure plate. Tighten the attaching bolts to 27-39 Nm (20-29 lb-ft).
Clean the oil pan, oil pump and oil pump screen cover and tube (6622). Prime the oil pump by filling the inlet port with engine oil and rotating the oil pump intermediate shaft (6A618) to distribute oil within the housing. Install the oil pump and oil pan.
Install generator and mounting bracket.
Install the oil filter.
Install the spark plugs, distributor cap and distributor to spark plug wires. Connect the distributor to spark plug wires and ignition coil to distributor high tension wiring.
Install the engine in the vehicle.
CAUTION: To prevent oil from entering the PCV system during air-powered oil fills, the closure hose should be disconnected from the oil fill pipe (6A868) and positioned away from the oil source. Cover the hose port with a shop towel to prevent oil from spilling onto the engine during oil fill. Reconnect the closure hose after the oil has been filled to the proper level.
Fill crankcase.