Kelly_H
Young Grasshopper
Well boo, I just realized that I put this in non-Mustang related general discussion instead of Mustang-related general discussion... oops. Someone move it if necessary, or don't, it's all good 
Ok, I admit it, I'm about to copy text over from one forum onto the other, but it really is a long story... call it the story of the week and read a little bit when you're bored every day or something, I don't care. To preface it, I am currently in Austin, TX, where I am apparently going to live for a couple of years (someone was dumb enough to decide I looked like a good graduate student). Now the problem is that Jane is in North Carolina, and her engine is on an engine stand with its guts hanging out and a different engine that works just as well as the old one (that is, it doesn't) is in her engine bay. Obviously, things are not as they should be! And here's why:
I drove Jane home to NC from CO a couple months back, arriving on July 13th. I went up to Chas's (my bodywork and paint guy / secondary father / ultimate hot rodder friend) to formulate a plan - Jane was in dire need of a clutch (it was older than I am), was seriously down on power (has been since the beginning of this year), and was having some weird cooling issues (running warmer on the freeway and at idle). We figured we would tackle the clutch first, then mess with the engine and cooling. I ordered parts and then went to Mustang Week because, well, I didn't want to miss out on the fun
I needed to drive to Austin, Texas on August 13th but I had plenty of time to do the clutch and figure out what little issue was plaguing Jane... or so I thought. From here on out I'll list everything by date.
Tuesday, 7/21:
Put Jane up on the lift (yes, I am fortunate enough to have access to Chas's lift) and pulled the transmission. This puppy has been leaking for quite some time so I thought that it would be a good opportunity to reseal everything. We took the transmission's top cover off and found that it was PERFECT inside - absolutely pristine. Must have been rebuilt. So we just resealed everything to ensure it wouldn't leak and left it alone.
The clutch was old and pretty worn but the flywheel looked perfect with no wear on it whatsoever. Awesome.
Wednesday, 7/22:
Installed the new clutch - a new 10" RAM diaphragm clutch. Reinstalled the transmission with no issues.
Thursday, 7/23:
On to the loss of power problem! Chas agreed that Jane sounded very flat, almost like she wasn't running on all 8 cylinders. We checked spark and it was good. Changed the plugs just in case and then went for a test drive. No improvement.
Double-checked the timing (10 initial, 36 all in) and the adjustment of the valves (dead on). Went for a test drive again, still no improvement.
Oh yeah, and that brand new clutch? Bad right out of the box. Heaviest pedal you could ever imagine and it was either all-on or all-off with no ability to feather it at all. Yes, it was installed right. And no, it wasn't supposed to be like that. So now we know that we need a new clutch - thus invoking the vicious "Jane's Law of Threes", which states that any part that is changed on the car must be changed three times. The original clutch makes one, the replacement (bad) clutch makes two, and the new clutch... well, hopefully it'd be three.
This is where it starts to get hairy. If you've got good spark, good fuel, good timing, and everything is properly adjusted... well, the dang thing should run well. So we rigged a dial indicator up to roughly measure the lift of the cam from the pushrods, just to check if anything had obviously gone flat. Well, the good news is that the cam wasn't wiped. But the readings were kind of all over the place so we concluded that it was pretty worn. This is interesting because this engine is a fairly fresh rebuild (~40,000 miles on it since the rebuild by the PO in the 80's). We started getting curious. Too curious.
So I took everything off of the front end of the engine (no small feat when you've got A/C, power steering, a mechanical fan with fan clutch, and a shroud all wrangled in there) and pulled the timing cover. We found that the timing chain was stupid stretched. There was so much slack in it that I could almost pull it off of the sprocket. Hello, problem one.
Well, a bad case of the "while I'm at it"s struck. I figured that if I had the front end of the engine off already and knew that the cam was worn, I might as well replace the cam. Thus...
Friday, 7/24:
I removed all of the extraneous stuff in preparation for removing the engine from the bay. While it's possible to change the cam out in the engine bay, I figured I would properly repaint the bay while I was at it... so the engine had to come out.
The whole time I was looking at that engine hoist I was thinking about the old saying - that an engine hoist is a tool used to test the tensile strength of all objects you've forgotten to disconnect from the engine
I made sure that wouldn't happen to me.
Saturday, 7/25:
Pulled the engine! It came out easily and I didn't have to test the tensile strength of anything. Suspiciously successful. We took it out with the transmission attached so that we could swap out the offending clutch at the same time.
Report this image
We pulled the cam out and surprise, surprise, no part numbers or any identifier on it. It was worn but not flat and not damaged, so that was good at least. The wear indicated that the cam had been in the car a whole lot longer than the other newer parts and we suspected that it had been pulled out of a different car.
I didn't have a degree wheel so we stuck it back in the engine and used the dial indicator to measure lift and duration as precisely as possible so that I could use the specs to buy a new cam with similar specs. I would have gotten a degree wheel but there were none available in my area and I didn't want to wait 2 days for one to ship, then another 2 days for a new cam based on my old cam, so I did the best I could.
I turned the engine over on the stand just to see what the bottom end looked like. All of the pistons were tight with no play in them and the bores still had really prominent crosshatching - a good sign! But as I looked closer at the bottoms of the pistons, I noticed something... several somethings. Yes, the previous owner had assembled the engine with not one, not two, but THREE different brands of pistons. How in the hell they all worked together happily is beyond me. The engine was officially upgraded to "built by a rocket scientist" status at that point.
Now, some of you may be thinking that a reasonable person would mediate this problem! But I, being a rational but unreasonable person, concluded that they were happy that way (after all, the engine had been running fine for many, many miles) and thus that they would not want to be touched. So I turned a blind eye. And no, they didn't end up being the source of any future problems in this post
Moving on...
Ok, I admit it, I'm about to copy text over from one forum onto the other, but it really is a long story... call it the story of the week and read a little bit when you're bored every day or something, I don't care. To preface it, I am currently in Austin, TX, where I am apparently going to live for a couple of years (someone was dumb enough to decide I looked like a good graduate student). Now the problem is that Jane is in North Carolina, and her engine is on an engine stand with its guts hanging out and a different engine that works just as well as the old one (that is, it doesn't) is in her engine bay. Obviously, things are not as they should be! And here's why:
I drove Jane home to NC from CO a couple months back, arriving on July 13th. I went up to Chas's (my bodywork and paint guy / secondary father / ultimate hot rodder friend) to formulate a plan - Jane was in dire need of a clutch (it was older than I am), was seriously down on power (has been since the beginning of this year), and was having some weird cooling issues (running warmer on the freeway and at idle). We figured we would tackle the clutch first, then mess with the engine and cooling. I ordered parts and then went to Mustang Week because, well, I didn't want to miss out on the fun

Tuesday, 7/21:
Put Jane up on the lift (yes, I am fortunate enough to have access to Chas's lift) and pulled the transmission. This puppy has been leaking for quite some time so I thought that it would be a good opportunity to reseal everything. We took the transmission's top cover off and found that it was PERFECT inside - absolutely pristine. Must have been rebuilt. So we just resealed everything to ensure it wouldn't leak and left it alone.
The clutch was old and pretty worn but the flywheel looked perfect with no wear on it whatsoever. Awesome.
Wednesday, 7/22:
Installed the new clutch - a new 10" RAM diaphragm clutch. Reinstalled the transmission with no issues.
Thursday, 7/23:
On to the loss of power problem! Chas agreed that Jane sounded very flat, almost like she wasn't running on all 8 cylinders. We checked spark and it was good. Changed the plugs just in case and then went for a test drive. No improvement.
Double-checked the timing (10 initial, 36 all in) and the adjustment of the valves (dead on). Went for a test drive again, still no improvement.
Oh yeah, and that brand new clutch? Bad right out of the box. Heaviest pedal you could ever imagine and it was either all-on or all-off with no ability to feather it at all. Yes, it was installed right. And no, it wasn't supposed to be like that. So now we know that we need a new clutch - thus invoking the vicious "Jane's Law of Threes", which states that any part that is changed on the car must be changed three times. The original clutch makes one, the replacement (bad) clutch makes two, and the new clutch... well, hopefully it'd be three.
This is where it starts to get hairy. If you've got good spark, good fuel, good timing, and everything is properly adjusted... well, the dang thing should run well. So we rigged a dial indicator up to roughly measure the lift of the cam from the pushrods, just to check if anything had obviously gone flat. Well, the good news is that the cam wasn't wiped. But the readings were kind of all over the place so we concluded that it was pretty worn. This is interesting because this engine is a fairly fresh rebuild (~40,000 miles on it since the rebuild by the PO in the 80's). We started getting curious. Too curious.
So I took everything off of the front end of the engine (no small feat when you've got A/C, power steering, a mechanical fan with fan clutch, and a shroud all wrangled in there) and pulled the timing cover. We found that the timing chain was stupid stretched. There was so much slack in it that I could almost pull it off of the sprocket. Hello, problem one.
Well, a bad case of the "while I'm at it"s struck. I figured that if I had the front end of the engine off already and knew that the cam was worn, I might as well replace the cam. Thus...
Friday, 7/24:
I removed all of the extraneous stuff in preparation for removing the engine from the bay. While it's possible to change the cam out in the engine bay, I figured I would properly repaint the bay while I was at it... so the engine had to come out.
The whole time I was looking at that engine hoist I was thinking about the old saying - that an engine hoist is a tool used to test the tensile strength of all objects you've forgotten to disconnect from the engine

Saturday, 7/25:
Pulled the engine! It came out easily and I didn't have to test the tensile strength of anything. Suspiciously successful. We took it out with the transmission attached so that we could swap out the offending clutch at the same time.

Report this image
We pulled the cam out and surprise, surprise, no part numbers or any identifier on it. It was worn but not flat and not damaged, so that was good at least. The wear indicated that the cam had been in the car a whole lot longer than the other newer parts and we suspected that it had been pulled out of a different car.
I didn't have a degree wheel so we stuck it back in the engine and used the dial indicator to measure lift and duration as precisely as possible so that I could use the specs to buy a new cam with similar specs. I would have gotten a degree wheel but there were none available in my area and I didn't want to wait 2 days for one to ship, then another 2 days for a new cam based on my old cam, so I did the best I could.
I turned the engine over on the stand just to see what the bottom end looked like. All of the pistons were tight with no play in them and the bores still had really prominent crosshatching - a good sign! But as I looked closer at the bottoms of the pistons, I noticed something... several somethings. Yes, the previous owner had assembled the engine with not one, not two, but THREE different brands of pistons. How in the hell they all worked together happily is beyond me. The engine was officially upgraded to "built by a rocket scientist" status at that point.
Now, some of you may be thinking that a reasonable person would mediate this problem! But I, being a rational but unreasonable person, concluded that they were happy that way (after all, the engine had been running fine for many, many miles) and thus that they would not want to be touched. So I turned a blind eye. And no, they didn't end up being the source of any future problems in this post

Moving on...
Last edited: