So I've had my '91 Bronco 5.0 for almost 2 years and love this vehicle! Other than some regular maintenance items, I have driven it everyday to and from work with very few problems. I started with 139,000 miles and it currently is up to 163,000.
The 5.0 has never been strong, but it has started and run every day! About 3 months ago, however, it started losing water. Slowly at first, but more and more each week, until last week, water was pouring out the bottom as fast as I was pouring it in! I initially thought it was the water pump, but a local shop said it was the timing cover...I'm not sure, but either way, it was leaking water as fast as I could put it in!
So, I started collecting parts to swap the 5.0 with an inline six. I've always liked the six, it's simplicity, reliability and torque. And, if it picks up a little extra MPG's, that's a win too!
This weekend, I started the engine swap. BTW, this is the first time I've ever replaced an engine, but I've been reading articles on this forum and others, and believe that I am as prepared as I can be.
I've taken some pictures along the way to document what I did and will point out any particular areas of difficulty if someone else attempts this swap.
Rented this from Sunbelt Equipment for $29/day. Best news? Rent it on Saturday and keep it until Monday for 1 day's rental!:
All connections between the engine and chassis disconnected, and putting on the lift chain:
This part went really easy...started at about 1pm Saturday and reached this point by about 6pm. Ready to separate the engine from the transmission...about to hit a major roadblock!
HINT: It is CRITICAL to know the number of bolts that attach the engine and transmission! Some are hard to see and if you don't get them all, you will waste a LOT of time and effort!
The Ford 5.0 has 6 bolts that connect the engine and transmission.
There are also 4 nuts that attach the flexplate to the torque converter. You simply remove the inspection plate on the transmission, and remove the nuts one at a time. You or someone, will have to rotate the engine so that you can access all four.
Once all nuts and bolts have been removed, I lifted the engine so that the engine mounts were clear of the frame. I then put a 2x4 under the transmission and lifted it with a hydraulic lift and heard a distinct "pop" as the engine and transmission separated.
I then started to raise the engine and move it forward to clear the hood and radiator support. This is the exciting part!
Out with the old and in with the New!
That's it for now...tomorrow, replace the 5.0 engine perches with the 4.9 perches, put in the new motor mounts and mount the six!