Dad's Truck

[Lvnmarks]

Last year I acquired my dad's old 1997 F150XLT, with a 5 speed manual transmission, 4.2L V6 and 4 wheel drive. It sat it a barn for the last 17 years getting driven once and a while, but for the most part of the last couple years it just sat. Recently the clutch stopped working and I was leaking coolant, so I decided to start taring into it.

 

[Lvnmarks]

Got her into the garage and started to drain the fluids.

 

[Lvnmarks]

Torsion bars would not come out, even after heating them with a torch. Removed the whole front suspension and pulled out as an assembly, from there I was able to get the bars out, unfortunately I had to cut the control arms, but they needed to get replaced anyway.

 

[Lvnmarks]

Torsion bars would not come out, even after heating them with a torch. Removed the whole front suspension and pulled out as an assembly, from there I was able to get the bars out, unfortunately I had to cut the control arms, but they needed to get replaced anyway.

 

[Lvnmarks]

Pulled the exhaust, transfer case and drive shafts, managed to break all the exhaust manifold studs, what a shock.... Also broke the two bolts that go through the oil pan to the bell housing, damn rust.

 

[Lvnmarks]

One reason the clutch wouldn't engage was because of the mice nest packed in the pressure plate.

 

[Lvnmarks]

Right now the transmission is off at the shop getting new synchro's and other new bits installed. But while on the subject of mice, I replaced the stock carpet a few months ago and had to disassemble 80% of the interior to get all the poop and nest out...I hate mice.

 

[Lvnmarks]

So while the transmission is off being resurrected, I decide to tackle the engine leak, up review of the procedures and items that needed to be addressed, pulling the engine was the next step. Things where going well until I started to take off the fan clutch, the book said it was L/H threads, Internet said it was L/H threads, auto parts guy said it was L/H threads...it was R/H threads. So after that, unbolted the motor mounts, removed the upper intake and disconnected all the electrical and vacuum lines. The engine came out fairly easy considering the transmission/exhaust/starter were already pulled.

 

[Lvnmarks]

Found the source of my exhaust leak, EGR line was rusted through. As I was taking the line and fitting off, the threads in the manifold stripped, so now I can add exhaust manifolds to the list, which works out because the studs were already broken an a new one comes with clean ones.

 

[Lvnmarks]

Removed the lower intake and cleaned the mating surfaces off.

 

[Lvnmarks]

Started on the exhaust side too...broke a stud in the head, I'm getting tired of this. cleaned and ready for new gaskets.

 

[Lvnmarks]

Cleaned the back side of the engine as well since I am there.

 

[Lvnmarks]

Removed the water pump, harmonic balancer and timing cover, all of which are getting new gaskets.

 

[Lvnmarks]

While the drive train is out I'm going to address some of the rust on the body and clean the engine bay.

 

[Lvnmarks]

Going to put some parts in my sand blast cabinet to clean them off and paint them. I know this truck is rusty but it has some sentimental value and I would like this thing to be on the road at least another 10 years.

 

[chris2523]

mice in the clutch huh, thats a new one.

 

[tixer]

Eric! You've been busy! This forum is overdue for a nice build thread, too. I'm glad to see this here.

I wonder if Ford has approved mouse nesting for clutch use. I suspect not. Kinda makes me wonder if you could have burned through it with a little work, had you known that was the culprit.

I wonder what the v6 sounds like with headers and strait pipes..

 

[Lvnmarks]

Wish I was working on the Lincoln but this needed to be done, can't live without a truck.

Yup, mice and 20 years took its toll, transmission guy says he has seen it before, just not a common failure. Slave cylinder was leaking as well.

I found headers but they're cheap and I'm guessing they will fail in a few years, looks like thin steel and poor welds. Best just to put logs back on and not have to worry about it.

I want this truck to be quiet, I even found a good write up for installing a Mark VIII fan, ditching the fan clutch...no project is complete in my garage with out some form of Mark VIII part in my cars.

 

[billcu]

Nice work. You might want to check out evapo rust, it is amazing at removing rust:

https://www.evapo-rust.com/

 

[Lvnmarks]

Got the transmission back at the end of January, replaced all the bearings, syncros, brass blocs, slave cylinder and repainted it.



Got the engine torn down to the long block, replacing the intake, valve covers, oil pan, timing cover and water pump gaskets.



.