front cam cap cracked--help!!

[BruceH]

Good to know. Did you machine your spare cap?

No. It worked. I did remove a small amount of material with polishing compound (flitz metal polish) and a socket. IIRC it was a 3/4 socket that fit the radius of the cap almost perfectly. I had to smooth some radial scratches that were in the scrap cap.

Others have had caps line up. Like I said in an earlier post Ford has a very consistant process for reaming the cam bores.

You will have to take this one step at a time. First try the weld. If the welder screws up then go to the cap swap. If the cap doesn't line up then you are talking about taking the head off and having it reamed. The bad part about that is if it's off enough to need an alignment the chances are that the bore will end up with excessive clearance. At that point you are hosed and need a new head.

 

[Roush05]

I'll know about the weld in about 2 hours. I will be SOL if i need a new head. I'm hoping it doesn't come to that. As far as the cap lining up, will it be obvious if it's off? If the cam turns without scraping/grinding, is that all I'm looking for?

 

[BruceH]

I'll know about the weld in about 2 hours. I will be SOL if i need a new head. I'm hoping it doesn't come to that. As far as the cap lining up, will it be obvious if it's off? If the cam turns without scraping/grinding, is that all I'm looking for?

I put the cap on without a cam and checked the mating joint with my finger. It felt just as smooth as the other caps. The next test was plastigauge with the cam in place and cap torqued. IIRC it was just under .002". Ford calls for .001-.003. From there we still weren't certain if it was round enough but didn't have a tool to measure concentricity so we put it together. We checked everything we were capable of checking and it seemed like a low risk potential. It worked.

 

[Roush05]

Okay, good deal. Thanks for all the help!

 

[Mustang30212]

Good luck!

RH

 

[crownaviation]

I'll know about the weld in about 2 hours. I will be SOL if i need a new head. I'm hoping it doesn't come to that. As far as the cap lining up, will it be obvious if it's off? If the cam turns without scraping/grinding, is that all I'm looking for?

You won't need a head.

Wow! Have never seen one welded (or broke). I was thinking. have two caps I can send (both the left side). I know for certain that alteast one of those are at the machine shop still (came off an 06). The other is off an 08 but should be the same. You can try them both and just send back the one you don't use. I won't be able to get to the machine shop until Tuesday due to the holiday. I can send the one in within the next hour... have it in my hand.

Good luck eithr way. My email is [email protected] if you need to reach me. I will have the cap boxed up and with me when I leave the house. Hope the welding works.

 

[S197gt07]

Any updates man?

 

[Roush05]

A bit late to respond, but I have an update. Currently taking a short break to eat a sandwich.


Update: We got the piece welded, it looks plenty sturdy. Had to grind a small bit on the inside to make clearance for the cam. We had to go get a grinder and then go back to my house to grind it. Anyway, that is what took most of the time. We just completely finished the driver's side and changed the spark plugs while we were at it. Next is the passenger side, which should be done in an hour or an hour and a half. Even though this has sucked, I have learned a lot about the process, which was one of my goals for this. Always think positive. lol.

Inside(you can see the bit that needed grinding)

 

[Roush05]

Mods can close this. It's on and running fine! Thanks to everyone who helped! Look for a vid in the video section in a couple hours.

 

[ZmanM3]

Glad you got it fixed.

 

[BruceH]

Excellent!

 

[Roush05]

Thanks guys, you guys really saved me a lot of time and trouble. I'm about to post a vid(in the correct section of course ).

 

[weather man]

Do some oil testing. If you see a lot of aluminum, you may want to investigate. Good luck with your fix!

 

[UltraKla$$ic]

Well, one of two things could have happened when your "friend" attempted to tighten down the caps with the motor loaded. One was he could have easily pulled the threads out of the head while trying to tighten the caps down and two, it happened, the cap that has very minimal integrity due to the soft metal and thin aspects of it's function, cracked.

Although you got it welded and some may think all is well, I question the longevity of the part's tolerances vs. spinning camshaft/very small oil journal if you may be visiting this potential problem sooner than later. I hope not, but I'd be saving for a "better" fix....IMO.

OR trade for a 5.0. LOL!

 

[stkjock]

Mods can close this. It's on and running fine! Thanks to everyone who helped! Look for a vid in the video section in a couple hours.

We don't close threads when things get resolved. They are left for others to find and use as needed.

 

[mustangmike6996]

are you sure you installed the cams on the correct of the engine?

 

[crownaviation]

Well, one of two things could have happened when your "friend" attempted to tighten down the caps with the motor loaded. One was he could have easily pulled the threads out of the head while trying to tighten the caps down and two, it happened, the cap that has very minimal integrity due to the soft metal and thin aspects of it's function, cracked.

Although you got it welded and some may think all is well, I question the longevity of the part's tolerances vs. spinning camshaft/very small oil journal if you may be visiting this potential problem sooner than later. I hope not, but I'd be saving for a "better" fix....IMO.

OR trade for a 5.0. LOL!

I sent him another cap. Hopefully the weld will last/not cause additional problems! Did the others that have tried this experience any long term issues?

Good luck with the fix man!

are you sure you installed the cams on the correct of the engine?

There is only one way they will fit due to different lengths

 

[Roush05]

Well, one of two things could have happened when your "friend" attempted to tighten down the caps with the motor loaded. One was he could have easily pulled the threads out of the head while trying to tighten the caps down and two, it happened, the cap that has very minimal integrity due to the soft metal and thin aspects of it's function, cracked.

Although you got it welded and some may think all is well, I question the longevity of the part's tolerances vs. spinning camshaft/very small oil journal if you may be visiting this potential problem sooner than later. I hope not, but I'd be saving for a "better" fix....IMO.

OR trade for a 5.0. LOL!

It was a friend. I was the one that realized what happened. The caps were never torqued down, so I doubt that the threads were affected.

Anyway, I have another cap on the way thanks to crown, and I have always been under the impression that a weld is stronger than the initial metal?

 

[UltraKla$$ic]

My reply is really just me thinking out loud. BruceH and the others are definitely advice you can trust. About the "friend", I was just being sarcastic. I really hope things go well and you never have any issues from this.


Good luck and enjoy the Hotrods. Also, it was awfully kind of crownaviation to send another cam cap to help with the situation. Props to him!

 

[JEWC_Motorsports]

Props to Bruce, that's why I love this place. Op glad its up and running.