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Broken front engine cover and T stat housing


E.Marquez

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DIRTY, SUMOBITCH, LYING, ASSHOLE previous owner.

 

My car WAS wrecked......:nonono:

 

I have seen a few clues over the last few months..., but nothing I could call the guy a dirty POS..on.....

 

But as I went to replace a leaking right valve cover gasket, I found the timing cover cracked in two spots directly behind the mounting point for the thermostat housing, at the T stat housing mount is cracked from point to point. And the lower front valve cover stud was bent in an S shape on the end that threads into the motor.

 

This car was either hit in the front right or the motor was removed and dropped, rammed into something on the front right busting the parts mentioned above.. All that RANT aside.....

 

Need some insight

 

So........ T stat housing is a no brainier to fix, it's a simple remove and replace.

 

But the engine front cover..

 

 

Looks like I can get to the entire front of the engine by removing radiator to bumper as i did when I installed the new damper, C&R cooler, and radiator. .. but fitment to the the oil pan I'm not sure of...

 

 

****.............

:banghead::banghead::banghead::banghead::banghead:

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Mechanical Catalog - 2007 - Ford - MUSTANG

engine, camshaft & timing, front cover Mustang 5.4L DOHC

 

$593.99

 

Mechanical Catalog - 2007 - Ford - MUSTANG

engine, camshaft & timing, front cover gasket Mustang Left 5.4L DOHC

 

$7.84

 

Mechanical Catalog - 2007 - Ford - MUSTANG

engine, camshaft & timing, front cover gasket Mustang Center 5.4L DOHC

 

$8.91

 

Mechanical Catalog - 2007 - Ford - MUSTANG

engine, camshaft & timing, front cover gasket Mustang Right 5.4L DOHC

 

$7.52

 

Mechanical Catalog - 2007 - Ford - MUSTANG

engine, camshaft & timing, front cover seal Mustang 5.4L DOHC

 

$7.47

 

Collision Catalog - 2007 - Ford - MUSTANG

cooling system, cooling, radiator & components, lower housing 5.4 LITER

 

$277.96

 

Total not including oil, filter, coolant $903.77 :fm:

 

What did I forget?

I have a new damper bolt on hand..so did not add that.

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So a few pictures, as I had it apart again this morning..... .

 

crackfrontenginecover.jpg

That one shows one of the cracks in the front engine cover, and you can just see that the damaged section is displaced rearward.

 

brokentstathousing.jpg

 

And the broken housing.....

 

Decided to weld the housing today... as that broken piece could shift and lay on the SC belt.

 

The oil and crud is there from the valve cover seal leaking at the cracked area of the cover. I think it is actually sealed right now, as I used (ie ruined ) RTV on the rubber valve cover gasket when i put it back the other day.

 

So looking for a good used front engine cover, but if not located in a few days, I'll buy a new one from Tousley along with the other parts.

 

The T stat housing may not be replaced depending on how it comes out after repair today.

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E M Ya ever thought of talking with the last owner about this?

 

 

Yes, but to what end?

 

It'll be a he said she said. We checked the CARFAX.. it was clean. We ASKED and were told no wrecks. We saw no evidence at the time of pre sale inspection of a wreck. And this is a three owner car (2 before us) The seller will just claim no knowledge.. . we have no proof he knew.... I can be mad..... but I cant really prove anything.... So I chose to just deal with it and move on.

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Welding was a pain in the butt.

No idea what type of AL alloy was in that cast piece, but it reacted like it was dirty, and I know it was not.

still.welding complete.

Choose to fit the parts together tightly and weld with no gap.. But that meant some misalignment as the cast part bent some before cracking.

 

Wanted both mounting surfaces parallel to each other so they would have no pre stress on the welded section and no extra stress on the engine cover.

 

Using the one good mounting point surface as the reference, clamped it down to to the mil table and cut the re-welded mount part parallel.

D2C21736-68CA-4FEA-AB60-D82BBE23A019-12216-00001A6400F25D14.jpg

 

799D2BB6-1531-4E4B-9790-8CFF0B4FBD34-12216-00001A63FAFC0F6F.jpg

 

Flipped it over and using BOTH mount points now to fix the part to the table, cut the other side parallel as well.

 

C4005E0D-ADD5-4261-95A7-655AED68E95A-12216-00001A63E8DF35D3.jpg

 

824C4FB8-7506-49A5-98D7-C4AA1F2BC356-12216-00001A6396AACE70.jpg

 

It's not pretty, but it is functional.

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