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Aluminator FAILURE
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<blockquote data-quote="jumperjack" data-source="post: 7192019" data-attributes="member: 65623"><p><strong>Look at this</strong></p><p></p><p>First thanks DoomsDay for the warning. Called my builder and had him check mine before he cranked it over and guess what, the damper is rubbing the cover just turning it over by hand. You can see where it started on the left and top in the pic. I have yo figure out what now. The car was all but ready to start today but looks like the engine has to come out. What FRPP is offering is BULLSHIT. We need to get together on this thing and find as many people as we can who have had problems. When my builder called FRPP today they told him they had not heard of this problem before. Another BULLSHIT for FRPP. Let's see if we can collectively come up with something and get some action. The one thing they do not like is bad publicity so I think I will hit every board I can tonight and this weekend and start posting for starters.</p><p>[ATTACH=full]922074[/ATTACH]</p><p></p><p></p><p></p><p></p><p>This is from Steve at Tousley</p><p>I spoke to one of the guys higher up than the guys at the tech line and the word from him is that they will pay shipping both ways on engines found to have this issue if the customer is willing to wait.</p><p> </p><p>They would then check the end play and adjust it as needed and sent the engine back to the buyer.</p><p> </p><p>The other option is that they are willing to pay some labor (very unusual) to have them fixed on site, they are basically willing to pay the same amount for repair that it would cost for the shipping.</p><p> </p><p>From what I understand it's simply due to a minor assembly error thats not terribly difficult to fix when it's out of the car of if the subframe is dropped.</p><p> </p><p>The mod motors use a single thrust washer on the rear of the thrust journal, not a double sided thrust washer like in the old days.</p><p> </p><p>This means that is the crank is not properly positioned when the thrust cap is bolted down the crank can be too far to the rear which can be an issue with the super tight pulley clearance on the Terminator.</p><p> </p><p>This is the procedure out of the manual for setting the crank.</p><p> </p><p> </p><p><strong>NOTE:</strong> Before assembling the cylinder block, all sealing surfaces must be free from chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.</p><ol> <li data-xf-list-type="ol">Install the upper main bearings into the cylinder block and the lower main bearing into the crankshaft main bearing caps. Lubricate the main bearings with clean engine oil.</li> </ol><p></p><ol> <li data-xf-list-type="ol">Install the crankshaft into the cylinder block.</li> </ol><p></p><ul> <li data-xf-list-type="ul"><img src="http://www.fordtechservice.dealerconnection.com/pubs/auxf/%7EWS-V-B/1586/A26584A.gif" alt="" class="fr-fic fr-dii fr-draggable " style="" /></li> </ul><p></p><ol> <li data-xf-list-type="ol"><strong><img src="http://www.fordtechservice.dealerconnection.com/pubs/auxf/%7EWS-V-B/3836/ani_caut.gif" alt="" class="fr-fic fr-dii fr-draggable " style="" /> CAUTION: Make sure the coated side of the thrust washer with the 5-mm wide oil grooves faces the crankshaft thrust surface.</strong><br /> Push the crankshaft rearward and install the crankshaft thrust washer at the back of the No. 5 main boss.</li> </ol><p></p><ul> <li data-xf-list-type="ul"><img src="http://www.fordtechservice.dealerconnection.com/pubs/auxf/%7EWS-V-B/1562/AA0361A.gif" alt="" class="fr-fic fr-dii fr-draggable " style="" /></li> </ul><p></p><ol> <li data-xf-list-type="ol">Loosely install the main bearing caps and the bolts.</li> </ol><p></p><ul> <li data-xf-list-type="ul"><img src="http://www.fordtechservice.dealerconnection.com/pubs/auxf/%7EWS-V-B/1575/AA0354A.gif" alt="" class="fr-fic fr-dii fr-draggable " style="" /></li> </ul><p></p><ol> <li data-xf-list-type="ol">Push the crankshaft forward to seat the crankshaft thrust washer and hold the crankshaft in the forward position.</li> </ol><p></p><ul> <li data-xf-list-type="ul"><img src="http://www.fordtechservice.dealerconnection.com/pubs/auxf/%7EWS-V-B/1568/AA0362A.gif" alt="" class="fr-fic fr-dii fr-draggable " style="" /></li> </ul><p></p><ol> <li data-xf-list-type="ol">Tighten bolts 1-20 in sequence shown in four stages.<ul> <li data-xf-list-type="ul">Stage 1: Tighten to 10 Nm (89 lb-in).</li> </ul><ul> <li data-xf-list-type="ul">Stage 2: Tighten to 25 Nm (18 lb-ft).</li> </ul><ul> <li data-xf-list-type="ul">Stage 3: Tighten to 40 Nm (30 lb-ft).</li> </ul><ul> <li data-xf-list-type="ul">Stage 4: Tighten an additional 90 degrees.</li> </ul></li> </ol><p></p><ul> <li data-xf-list-type="ul"><img src="http://www.fordtechservice.dealerconnection.com/pubs/auxf/%7EWS-V-B/1599/AA5328A.gif" alt="" class="fr-fic fr-dii fr-draggable " style="" /></li> </ul><p></p><ol> <li data-xf-list-type="ol">Install and tighten the cross-mounted bolts in two stages.<ul> <li data-xf-list-type="ul">Stage 1: Tighten to 40 Nm (30 lb-ft).</li> </ul><ul> <li data-xf-list-type="ul">Stage 2: Tighten an additional 90 degrees.</li> </ul></li> </ol><p></p><ul> <li data-xf-list-type="ul"><img src="http://www.fordtechservice.dealerconnection.com/pubs/auxf/%7EWS-V-B/1585/AA4317A.gif" alt="" class="fr-fic fr-dii fr-draggable " style="" /></li> </ul><p></p><ol> <li data-xf-list-type="ol">Check the crankshaft end play. For additional information, refer to <a href="http://www.fordtechservice.dealerconnection.com/renderers/reload_frames.asp?leftside=/pubs/content/%7EWS3B/%7EMUS%7ELEN/22/S3BS300L.HTM&rightside=/pubs/content/%7EWS3B/%7EMUS%7ELEN/22/S3BS300R.HTM&contenttype=WORKSHOP&workunit=S3B&market=US&language=EN&viewer=IE" target="_blank">Section 303-00</a>.</li> </ol><p>Heres the procedure for checking end play,</p><p> </p><p><strong>Crankshaft End Play <a href="http://www.fordtechservice.dealerconnection.com/pubs/content/%7EWS3B/%7EMUS%7ELEN/18/S3B30020.PDF" target="_blank"><img src="http://www.fordtechservice.dealerconnection.com/pubs/auxf/%7EWS-V-B/1527/adobe.gif" alt="" class="fr-fic fr-dii fr-draggable " style="" /> Printable View (79 KB)</a> </strong></p><p></p><p></p><p>Special Tool(s)<img src="http://www.fordtechservice.dealerconnection.com/pubs/auxf/%7EWS-V-B/1610/ST1214A.gif" alt="" class="fr-fic fr-dii fr-draggable " style="" />Dial Indicator Gauge with Holding Fixture </p><p>100-002 (TOOL-4201-C) or equivalent</p><ol> <li data-xf-list-type="ol">Use a Dial Indicator Gauge with Holding Fixture to measure crankshaft end play.</li> </ol><p></p><ol> <li data-xf-list-type="ol">Position the crankshaft to the rear of the cylinder block.</li> </ol><p></p><ol> <li data-xf-list-type="ol">Zero the indicator.</li> </ol><p></p><ol> <li data-xf-list-type="ol">Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.<ul> <li data-xf-list-type="ul">If crankshaft end play exceeds specifications, install a new crankshaft thrust washer or crankshaft thrust main bearing. Refer to the appropriate section in Group <a href="http://www.fordtechservice.dealerconnection.com/renderers/reload_frames.asp?leftside=/pubs/content/%7EWS3B/%7EMUS%7ELEN/17/S3BG03L.HTM&rightside=/pubs/content/%7EWS3B/%7EMUS%7ELEN/17/S3BG03R.HTM&contenttype=WORKSHOP&workunit=S3B&market=US&language=EN&viewer=IE" target="_blank">303</a> for the procedure.</li> </ul></li> </ol><p></p><ul> <li data-xf-list-type="ul"><img src="http://www.fordtechservice.dealerconnection.com/pubs/auxf/%7EWS-V-B/1622/AA3776A.gif" alt="" class="fr-fic fr-dii fr-draggable " style="" /></li> </ul><p></p><p> </p><p>For the ones that have not installed the engines yet it's simply a matter of checking end play, if it's good you're fine, if it's not then you have the option of having FRPP pay whatever they offer for resetting it or of having them drag it back to Detroit and let them reset it and ship it back.</p><p> </p><p>I'll do anything I can to help anyone with any issues they have with one of these but I don't get to make any of the actual decisions.</p><p> __________________</p><p> Tousley Ford Parts Depot, I am offering all OEM Ford and Ford Racing parts at 10% over cost to forum members.</p><p> </p><p>PM me or call me at 1-800-328-9552 ask for Steve or Mike M.</p><p> </p><p>Hey all, We now have online ordering!!</p><p> </p><p>Heres the link </p><p><a href="http://www.trademotion.com/PARTLOCATOR/INDEX.CFM?SITEID=214771" target="_blank"><span style="color: #0f476e">http://www.trademotion.com/PARTLOCAT...?SITEID=214771</span></a></p><p> </p><p>The e-mail tied to the site is <a href="mailto:TOUSLEYFORDPARTS@LIVE.COM"><span style="color: #0f476e">TOUSLEYFORDPARTS@LIVE.COM</span></a></p><p> </p><p>I hope this makes everyones life easier.</p></blockquote><p></p>
[QUOTE="jumperjack, post: 7192019, member: 65623"] [b]Look at this[/b] First thanks DoomsDay for the warning. Called my builder and had him check mine before he cranked it over and guess what, the damper is rubbing the cover just turning it over by hand. You can see where it started on the left and top in the pic. I have yo figure out what now. The car was all but ready to start today but looks like the engine has to come out. What FRPP is offering is BULLSHIT. We need to get together on this thing and find as many people as we can who have had problems. When my builder called FRPP today they told him they had not heard of this problem before. Another BULLSHIT for FRPP. Let's see if we can collectively come up with something and get some action. The one thing they do not like is bad publicity so I think I will hit every board I can tonight and this weekend and start posting for starters. [ATTACH=full]922074[/ATTACH] This is from Steve at Tousley I spoke to one of the guys higher up than the guys at the tech line and the word from him is that they will pay shipping both ways on engines found to have this issue if the customer is willing to wait. They would then check the end play and adjust it as needed and sent the engine back to the buyer. The other option is that they are willing to pay some labor (very unusual) to have them fixed on site, they are basically willing to pay the same amount for repair that it would cost for the shipping. From what I understand it's simply due to a minor assembly error thats not terribly difficult to fix when it's out of the car of if the subframe is dropped. The mod motors use a single thrust washer on the rear of the thrust journal, not a double sided thrust washer like in the old days. This means that is the crank is not properly positioned when the thrust cap is bolted down the crank can be too far to the rear which can be an issue with the super tight pulley clearance on the Terminator. This is the procedure out of the manual for setting the crank. [B]NOTE:[/B] Before assembling the cylinder block, all sealing surfaces must be free from chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear. [LIST=1] [*]Install the upper main bearings into the cylinder block and the lower main bearing into the crankshaft main bearing caps. Lubricate the main bearings with clean engine oil. [/LIST] [LIST=1] [*]Install the crankshaft into the cylinder block. [/LIST] [LIST] [*][IMG]http://www.fordtechservice.dealerconnection.com/pubs/auxf/%7EWS-V-B/1586/A26584A.gif[/IMG] [/LIST] [LIST=1] [*][B][IMG]http://www.fordtechservice.dealerconnection.com/pubs/auxf/%7EWS-V-B/3836/ani_caut.gif[/IMG] CAUTION: Make sure the coated side of the thrust washer with the 5-mm wide oil grooves faces the crankshaft thrust surface.[/B] Push the crankshaft rearward and install the crankshaft thrust washer at the back of the No. 5 main boss. [/LIST] [LIST] [*][IMG]http://www.fordtechservice.dealerconnection.com/pubs/auxf/%7EWS-V-B/1562/AA0361A.gif[/IMG] [/LIST] [LIST=1] [*]Loosely install the main bearing caps and the bolts. [/LIST] [LIST] [*][IMG]http://www.fordtechservice.dealerconnection.com/pubs/auxf/%7EWS-V-B/1575/AA0354A.gif[/IMG] [/LIST] [LIST=1] [*]Push the crankshaft forward to seat the crankshaft thrust washer and hold the crankshaft in the forward position. [/LIST] [LIST] [*][IMG]http://www.fordtechservice.dealerconnection.com/pubs/auxf/%7EWS-V-B/1568/AA0362A.gif[/IMG] [/LIST] [LIST=1] [*]Tighten bolts 1-20 in sequence shown in four stages. [LIST] [*]Stage 1: Tighten to 10 Nm (89 lb-in). [/LIST] [LIST] [*]Stage 2: Tighten to 25 Nm (18 lb-ft). [/LIST] [LIST] [*]Stage 3: Tighten to 40 Nm (30 lb-ft). [/LIST] [LIST] [*]Stage 4: Tighten an additional 90 degrees. [/LIST] [/LIST] [LIST] [*][IMG]http://www.fordtechservice.dealerconnection.com/pubs/auxf/%7EWS-V-B/1599/AA5328A.gif[/IMG] [/LIST] [LIST=1] [*]Install and tighten the cross-mounted bolts in two stages. [LIST] [*]Stage 1: Tighten to 40 Nm (30 lb-ft). [/LIST] [LIST] [*]Stage 2: Tighten an additional 90 degrees. [/LIST] [/LIST] [LIST] [*][IMG]http://www.fordtechservice.dealerconnection.com/pubs/auxf/%7EWS-V-B/1585/AA4317A.gif[/IMG] [/LIST] [LIST=1] [*]Check the crankshaft end play. For additional information, refer to [URL="http://www.fordtechservice.dealerconnection.com/renderers/reload_frames.asp?leftside=/pubs/content/%7EWS3B/%7EMUS%7ELEN/22/S3BS300L.HTM&rightside=/pubs/content/%7EWS3B/%7EMUS%7ELEN/22/S3BS300R.HTM&contenttype=WORKSHOP&workunit=S3B&market=US&language=EN&viewer=IE"]Section 303-00[/URL]. [/LIST] Heres the procedure for checking end play, [B]Crankshaft End Play [URL="http://www.fordtechservice.dealerconnection.com/pubs/content/%7EWS3B/%7EMUS%7ELEN/18/S3B30020.PDF"][IMG]http://www.fordtechservice.dealerconnection.com/pubs/auxf/%7EWS-V-B/1527/adobe.gif[/IMG] Printable View (79 KB)[/URL] [/B] Special Tool(s)[IMG]http://www.fordtechservice.dealerconnection.com/pubs/auxf/%7EWS-V-B/1610/ST1214A.gif[/IMG]Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent [LIST=1] [*]Use a Dial Indicator Gauge with Holding Fixture to measure crankshaft end play. [/LIST] [LIST=1] [*]Position the crankshaft to the rear of the cylinder block. [/LIST] [LIST=1] [*]Zero the indicator. [/LIST] [LIST=1] [*]Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play. [LIST] [*]If crankshaft end play exceeds specifications, install a new crankshaft thrust washer or crankshaft thrust main bearing. Refer to the appropriate section in Group [URL="http://www.fordtechservice.dealerconnection.com/renderers/reload_frames.asp?leftside=/pubs/content/%7EWS3B/%7EMUS%7ELEN/17/S3BG03L.HTM&rightside=/pubs/content/%7EWS3B/%7EMUS%7ELEN/17/S3BG03R.HTM&contenttype=WORKSHOP&workunit=S3B&market=US&language=EN&viewer=IE"]303[/URL] for the procedure. [/LIST] [/LIST] [LIST] [*][IMG]http://www.fordtechservice.dealerconnection.com/pubs/auxf/%7EWS-V-B/1622/AA3776A.gif[/IMG] [/LIST] For the ones that have not installed the engines yet it's simply a matter of checking end play, if it's good you're fine, if it's not then you have the option of having FRPP pay whatever they offer for resetting it or of having them drag it back to Detroit and let them reset it and ship it back. I'll do anything I can to help anyone with any issues they have with one of these but I don't get to make any of the actual decisions. __________________ Tousley Ford Parts Depot, I am offering all OEM Ford and Ford Racing parts at 10% over cost to forum members. PM me or call me at 1-800-328-9552 ask for Steve or Mike M. Hey all, We now have online ordering!! Heres the link [URL="http://www.trademotion.com/PARTLOCATOR/INDEX.CFM?SITEID=214771"][COLOR=#0f476e]http://www.trademotion.com/PARTLOCAT...?SITEID=214771[/COLOR][/URL] The e-mail tied to the site is [EMAIL="TOUSLEYFORDPARTS@LIVE.COM"][COLOR=#0f476e]TOUSLEYFORDPARTS@LIVE.COM[/COLOR][/EMAIL] I hope this makes everyones life easier. [/QUOTE]
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