The Perfect Vehicle -

The Truck : 1992 Ford F150

 

Things we learned overhauling (not rebuilding) the engine in our 1992 Ford F-150 extended cab 4×4, v8 5.0L.

Backstory:
There were water leaks that got bad enough we had F&F figure out where they were coming from. Radiator and water pump – logical. Timing chain cover, really?  Yep, lots of forum discussions.

So while doing this, Mike decided to replace the oil pan gasket, since the truck has been leaking oil forever and that leak was getting worse.

How do you replace the oil pan gasket? Pull the engine or axle. He pulled the engine. It helps to have a friend with an engine lift.

This page contains notes on specs and procedures and is a work in progress. Ford used the 5.0L small block engine in trucks from at least 1987 to 1996 according to my Chilton’s manual.

General Info

  • Battery group number: 65
  • Firing order for 302 V8 engine: 1-5-4-2-6-3-7-8
  • Ignition timing:  10 degrees before top dead center
  • OEM spark plug: Motorcraft ASF-42P
  • Spark plug gap: 0.054 (54 thousandths of an inch)

Emissions System

Fuel Injectors

Take your fuel injectors to a local shop (if you’re in a metro area) and have them cleaned/inspected.

Shop around, but in suburban Seattle the price was about the same as doing it from an online service. This is a lot less expensive that buying new ones, and the shop will tell you if one is bad. Don’t put them back in the engine without this step!

 

Heater Core

Timing Chain/Cover + Harmonic Balancer (Vibration Damper)

Details on removal and installation of the timing chain cover and harmonic balancer on a separate page.

 

Timing Chair

 

 

BoxWrench has a great set of YouTube videos:

Torque Specs Ford V8, 5.0 L, 302 Engine

From FelPro Torque Tables (pdf)
302 (5.0l) : Flanged Hex Head bolts: 1st 25-35, 2nd 45-55, 3rd turn 85-95 degrees

 

Item Torque ft #s
Alternator mounting bolts to 20
Alternator pivot bolt to 50
Alternator adjusting arm bolt to 40
Crankshaft pulley 70-90
Exhaust manifold 18-24
Intake manifold, upper to lower 12-18
Intake manifold, other 23-25
Spark plug 10-15
Water pump 12-18
Cylinder head, w/flanged bolts Step 1: 25-35
Step 2: 45-55
Step 3: 90
Cylinder head, wout/flanged bolts Step 1: 55-65
Step 2: 65-72
Sources: Chilton’s, AllData, etc. Not forums.

 

The following data sourced from BoxWrench 
Verify your engine specs with a service manual for your year and model; always torque bolts in three equal increments.
Bolts or Parts Lube or Sealer Torque to:
Bellhousing
(Transmission to Block)
Engine Oil 25 ft-lbs.
Cam Bolt (upper gear) Thread Locker 40 ft-lbs.
Camshaft Thrust Plate Thread Locker 10 ft-lbs.
Centerbolt
(Harmonic Damper)
Thread Locker 90 ft-lbs.
Clutch Pressure Plate Thread Locker 35 ft-lbs.
Connecting Rod
260, 289, 302
*289HP and Boss 302
Engine Oil 25 ft-lbs.
*45 ft-lbs.
Cylinder Heads Engine oil
(blind hole)
Sealer
(water jacket)
70 ft-lbs.
Flexplate (Automatic)
Flywheel (Clutch)
Thread Locker 85 ft-lbs.
Front Cover Engine Oil 20 ft-lbs.
Intake Manifold
(Cast Iron Heads)
Non-Hardening Sealer 25 ft-lbs.
Main Caps Engine Oil 70 ft-lbs.
Oil Pump Engine Oil 25 ft-lbs.
Oil Pan Engine Oil 15 ft-lbs.
Outer Main Cap Bolts Engine 40 ft-lbs.
Rocker Arms Engine Oil 20 ft-lbs.
Valve Cover Engine Oil 10 ft-lbs.

 

Other Ford F150 specs found along the way

 

1990 Ford F150 302 Engine Rebuild / Overhaul an Engine

Michael Thalis published an extensive series on YouTube of his experiences rebuilding his 1990 F150 302.

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