I'm in the middle of replacing my front engine cover and my pulley seized and it actually pulled it off the front cover breaking the mount off.
So far in tear down to replace I have found all the nice things that seem to plague this motor over time.



Didnt get a picture but I found my small leak at radiator where it was dripping trans fluid very slowly. Picked up a new 2.2 2 row radiator to replace.


Passenger side rear exhaust bolts were both snapped off as well as one on drivers side. Never heard any exhaust leaks or tick so surprised to find these. Straight edged the manifold and it warped at rear cylinder. Needs new one. LUCKILY besides the one in the block that snapped below surface they all came out easily. I was able to reverse drill the small stud and then use extractor to pull out. The part was actually turning in block so I knew it would come out. Heads are fine and no pitting from leak luckily.




Starting to get all the parts and decided to change the crossover gaskets in the intake manifold also since it was off and have seen a few cracked here. Found mine was also cracking in spots and needs replacing:



Cant really complain as the truck really hasn't needed much over the last 15 years but was surprised to find all of these at once.


Looks like the simple repair just got a little longer and more costly. Still not bad for 15 years of use.

 

You can probably save the front cover if you drill and extract that bolt remainder

 

There is no bolt remaining in there. It snapped the nipple part off that the idler pulley mounts onto and pulled it out of the cover. I actually found it still stuck in the pulley after it snatched it off. It destroyed the thread when it yanked out.
Here is the part that snapped off with the bolt

 

New cover done and idler pulley and tensioner replaced along with a few other items since I had it apart this far. Waiting on new intake and can get it back on the road. Really not hard to tear into it this far at all and put back together.

 

Replace your Trans mount or you'll break the manifold bolts again. It's wore out.

 

So that's what breaks them?

 

Yea, the bushing inside wears out, without a bushing, it's metal on metal, trans sinks, exhaust Y is tied to the trans and mount, so it sinks. That puts pressure at the rear exhaust studs and along with that metal to metal vibration, busts them off. Usually the passenger side first.

 

The mount is out as of a few minutes ago and was pretty easy to get off. It looks okay but for assurance I will replace. Any idea if the aftermarket ones are okay or look for OEM again.

Part number F85A-6D091-BA, CA, or DA depending if it was colored white, violet or yellow according to stamping. Mine is just rust colored now

I can pick one up at Advance Auto for less than 20 with discount if those are worth it.

 

My passenger side stud was broken when I did my head gaskets. I bought new studs and a new manifold, but I didn't change the transmission mount. Is there any difficulty in that?

BTW, engine looks really clean 2000FordStyle... mine is kinda brown.

 

Yea, they are cheap and fairly simple to replace. Support the trans in the back, then remove the trans support crossbar. 3 bolts/nuts on each frame rail and two dead center. The two in the center are trans mount nuts and part of what you'll be replacing. Easy job.

 

Yep, just got done with it all and new one back in. Picked mount up from advance auto part# Anchor 2870 for $17.12 out the door with lifetime warranty.
Hardest part of it all was loosening up cross member bolts as a few were close to exhaust but wrench helped on them. Luckily I live in pretty much snow free area with very mild surface rust in just a few spots. The old mount being one of them.

Took maybe an hr total to take old out and get new one from start to finish.

Old one wasn't in too bad shape visually..