Push piston pin out of connecting rod and piston by hand.
| Item | Part Number | Description |
|---|---|---|
| 1 | 6200 | Connecting Rod |
| 2 | 6135 | Piston Pin |
| 3 | 6102 | Piston |
| 4 | — | Piston Vise |
| 5 | — | Nylon Rod/Brass Drift |
Section 03-01D: Engine, Diesel, 7.3L | 1996 F-Series Workshop Manual |
Disassembly
NOTE: When replacing piston and connecting rod (6200), make sure to use the correct replacement part.
Remove connecting rod bearings (6211) from connecting rod and connecting rod cap.
Mark pistons to ensure assembly with same connecting rod and installation into cylinders from which they were removed.
Mark connecting rod to assure correct orientation to piston on reassembly.
To disassemble connecting rod from piston and piston pin assembly, remove piston pin retainers (6140) from each end of piston pin (6135) using appropriate snap ring pliers.
Push piston pin out of connecting rod and piston by hand.
| Item | Part Number | Description |
|---|---|---|
| 1 | 6200 | Connecting Rod |
| 2 | 6135 | Piston Pin |
| 3 | 6102 | Piston |
| 4 | — | Piston Vise |
| 5 | — | Nylon Rod/Brass Drift |
After piston pin is removed, separate piston from connecting rod. Remove all old piston rings from piston. Clean and inspect components. Refer to Pistons, Piston Pins and Piston Rings, and Connecting Rods in the Cleaning and Inspection portion of this section.
Assembly
Assemble piston to connecting rod. Position connecting rod into piston so that large chamfer of connecting rod journal faces the crankshaft fillet. The word camside and an arrow on the piston should point toward the camshaft (6250) when installed in cylinder block (6010).
Lubricate piston pin with specified engine oil. Align rod bore and piston bore and insert piston pin. Push piston pin with thumb and install piston pin retainers. Make sure that piston pin retainers seat fully in their grooves.
After checking piston ring end gap, assemble piston rings onto pistons to which they were fitted by using a suitable ring expander tool. This type of tool is recommended to avoid overexpansion of piston rings, and also to expand piston rings to a true circle to avoid distortion. Install piston rings onto piston in the following order: oil control ring, second compression ring and top compression ring. Space ring gaps 120 degrees apart.
Check ring side clearance (second compression ring).
