31 July 2016 - paint work

It rained most of the day, so I could not get anything painted.  Continued to cleanup engine to prep for paint.

30 July 2016 - brakes

Picked up the power booster today.  It looks exactly like the installed unit sans mounting plate(of course).  So I ordered a mounting plate and seal from WCCC.  It should arrive sometime next week.  So for now I will focus on cleaning and painting the engine, transmission, brackets, harmonic balancer and anything else I find.

Painted the harmonic balancer, ignition coil bracket and crankshat bolt & washer.  Still need to do touch up paint on the engine but the car cannot be moved from the garage until the brake system is finished.  I am waiting on a booster mounting bracket and seal, once those arrive I can install the booster then master cylinder and then I can safely move/park the car.

Need to clean up booster mounting location

 

old and new boosters

new and old booster reference images

New booster will get painted VHT Chassis Black

Reference image

Need to clean that area up.  I will use rust remover/inhibitor on those components and area.

 

29 July 2016 - Brakes

After talking with Darrell of WCCC about the power booster, it looks like I need to replace it.  So I will remove the old one today and put in an order for a replacement this weekend.  After this work I will only need to replace two remaining wheel cylinders and one flex hose up front and the flex hose on the rear axle.

I removed the power booster this evening.  The unit has a mounting plate with spacers and one of the spacers is spot welded to the booster and plate.  After doing a bit of research I found out that the booster is a knock off.  An OEM replacement would have a plate but would be removable.  So I cannot use the plate with the replacement booster.

I will pick up a replacement booster on saturday and check to see if that can be used with the booster mounting plate that WCCC has in stock.  If so I will order that Saturday and hopefully it will arrive by next week end. 

28 July 2016 - Brakes

Removed the master cylinder to replace it.  But I found out the master cylinder was leaking into the power booster.  So I removed the pushrod assembly from the power booster and cleaned up the power booster pushrod assembly then cleaned up the power booster.  I am doing some research to find out if the power booster needs to be replaced of if I can re-use the power booster and pushrod assembly.

pic of the power booster pushrod assembly

power booster pushrod assembly in pieces just after cleanup

pic of the two master cylinder lines that need to be replaced...

New master cylinder - gravity bleeding in progress

27 July 2016 - brakes

I worked on the brake system today, bled all cylinders and topped off the master cylinder reserviors.  I also sprayed Pb blast on the master cylinder fittings and bolts.  Some time this week I need to replace that and then re-bleed the brake system.

Took a look at the engine paint today and noticed some areas of engine where the paint is rough as if I didn't get the coverage right.  Tomorrow I will clean/prep the engine and re-paint those areas.  The crankshaft engine pulley and ignition coil clamp need to be painted too.  I also need to paint the engine mounts chassis black.

26 July 2016 - brakes / master cylinder

Picked up the master cylinder.

Need to inspect the brake system to see what I have done so far and read the blog posts

* need to bleed the brake system first and replace any components that need it, then replace master cylinder, re-bleed brake system.

Items to be replaced:

• wheel cylinder front right 
• wheel cylinder rear right and left
• rubber flex hose passenger front side
• rubber flex hose driver side rear

25 July 2016 - brakes

The brake master cylinder is in need of replacement.  I ordered a unit today and it will arrive tomorrow.  This week I will work on the brake system and the idler arm.

24 July 2016 - engine painting

Painted the engine today.  Cleaned up the garage after that so its not as dirty.  Cleaned up the engine mounts and ignition coil bracket so they can be painted tomorrow.  Also started painting the harmonic balancer and bolt.  I'll finish that tomorrow.

23 July 2016 - engine paint prep

Started cleanup and taping the engine for painting..  Weather permiting, I will move the Merc into the driveway and paint the engine and components in the garage

22 July 2016 - transmission

The transmission was ready for pick up today.  Its now in the garage on the cradle awaiting further maintenance.

21 July 2016 - Brakes / idler arm assembly

Before the engine/transmission is installed...

* Replace the master cylinder


Also the idler arm would be alot easier to replace with the engine/transmission out...

21 July 2016 - transmission shop

I got a call from the transmission shop today.  I was told that there are metal pieces/parts in the tranmission pan, and if I wanted to I could come on over to the shop and take a look, so I did.  The indications are that the torque converter was the source of the failure.  The rest of the transmission was ok and only needed a rebuild kit.  The shop went ahead and sent the torque converter to TCI to have it remanfactured.  I might be able to pick up the transmission on Monday of next week.

20 July 2016 - engine machine shop

I stopped by the engine machine shop to pick up the engine.

Here it is back in my garage and this is what it looks like at this point in time...

While I was looking over the engine to prepare it for painting, I noticed that a drain plug on the driver's of the block was missing.  I had one in my parts bin so I put sealer on it and installed it.  I also plugged up/covered all openings to of the engine.  I need to start painting the engine this week.  For the time being, I went ahead and installed the spark plugs

20 July 2016 - transmission shop

I dropped off the transmission at a local shop today.  They will probably have it ready by mid next week.  This is not a problem, I have a few things to do with the engine and body before the transmission is needed.

The transmission is a TCI sizzler series C4.

18 July 2016 - machine shop

Stopped by the machine today, and talked with the machinist.  He said the engine will be ready for pickup tomorrow afternoon.

ToDo list for engine
==========================
* paint entire engine and brackets duplicolor DE1601
* install harmonic balancer after painting
* install alternator brackets
* install engine to transmission plate then install flexplate
* seal all water ports/intake ports/exhaust ports
*
*


Take transmission to the shop for rebuild. 
 

16 July 2016

Continued with cleaning up the transmission.  Finished working on a wood cradle for the transmission, to make it easier to transport it, to and from the shop.

Purchased a replacement mounting pad for the transmission.

Also received the engine tools from summit racing,  a TDC indicator and an oil pump primer. 

Transmission pad as it should be installed on transmission

Transmission pad as it should be installed on transmission

 

oil pump primer on the left and the TDC indicator on the right

15 July 2016 - alternator brackets / engine-transmission plate / timing cover pointer / bellhousing inspection plate

Cleaned up and painted the alternator brackets, engine-transmission plate, timing cover pointer and bellhousing inspection plate.  Might need to do touch up coats but they look good to me right now.

Brackets after cleanup and painting(thermostat housing just happened to be in the box)

engine-transmission plate after cleanup and painting

After market - top, original part - bottom

After market - top, original part - bottom

 Started cleanup of the transmission to get it ready to take to the transmission shop.

Reference picture so I know where the switch, kickdown and spring hardware mount.

started cleanup of case and bellhousing.

started cleanup of case and bellhousing.

started cleanup of case and bellhousing.

14 July 2016 - alternator brackets

Cleaned up the alternator brackets.  Will paint the pieces tomorrow.  Going to use Duplicolor DE1601 Ford Blue.

 

Alternator brackets ready for painting(that wrist pin is not supposed to be there)

This is the color I will use for the engine(back of can)

Front of can

The engine stand I will use when I pick up the engine from the machine shop.  Added a couple of 2x4s(the left/right ones) to steady the engine/stand during transport from the machine shop

Engine to transmission shield.  Needs a little touch up work...

13 July 2016 - engine rebuild short block images

Here are a couple of pix of the short block after clean up, machining and bottom end installation.

 

12 July 2016 - Brake hardware

Here are some brake hardware that need to be installed.