[John W.]

GOT IT!!!!!

Yes, it took a bigger hammer and a bigger cold chisel. It still took quite a few blows to come loose, but I started to see a crack after just a few.


My bad, I said it was a 5lbs hammer previously, it's *only* 4lbs.



I took the wire brush to the crank end, but I think I'm going to need some emery cloth to really clean it up. It was rusty the entire depth of the sprocket around most of the crank.

[TurboRay]

<font color=dedfdf>................</font> :thumbup:

[John W.]

Well . . . One step forward, one step backwards.

Now that the lower sprocket is removed, I was able to inspect the front seal aluminum. And . . . it's really rough. There are stress cracks around each bolt holes, and one of the oil pan bolt bosses has cracks all around it.

So, along with my new (old) crankcase breather, I just ordered a new (old) front seal plate. Hooray?

It's a really good thing I'm doing this as a "hobby" because I could see myself getting really upset if this were an important project with goals and deadlines and stuff.

Also, put about 150 miles on the Falcon today! Then, found out the junkyard I was hitting is closed for the holiday weekend. Well, it was a good ride for Zoey-dog and I, and I made nearly 20mpg. She got to pee on new territories, so it's a win-win!

[John W.]

WOW! I just installed an MSD ignition box on the Falcon and I cannot believe how much smoother it is. It was running "good" before, but it had a stutter on cold starts. Now, it's as good as bacon.

I also have parts for the 2.3 coming in and reassembly has officially started. I have the head back on - not torqued down, just snugged down with a brand new gasket. The water pump and front seal are installed. New freeze plugs are in. New oil separator should arrive tonight.

I forgot all about the lower intake. I now have definite proof the oil separator was leaking, and for quite a while. The lower intake is soaked in oily gunk. So, that's soaking in cleaner now. I'm optimistic it will wipe clean, but really I suspect I have more wire brushes in my future.

[John W.]

A lot of progress this weekend! I have the intake side 80% back together. I'm still missing a distributor (well, there's something SITTING there, but I'm pretty sure it's ruined) and some rubber pieces that were rotten, but it's coming right along. The intake cleaned up pretty well, and I'm working on the valve cover & oil pan now.



And here's a pic of the CDI in the Falcon. I'm still blown away by how good it's running now.

[John W.]

"That rug really tied the room together, man." -- I found these Gen I "Thunderbird Special" Valve cover decals a few weeks ago. The top right corner came apart during install, but that will be under the intercooler anyway.

[John W.]

Just returned from my 20-yr High School reunion & put about 500 miles on the little Falcon, making just over 21mpg over the entire trip & almost 27mpg on the way down --- still on the 200 I6, which is running near-perfect!

Had a couple of classmates make comments like, "I pulled in and saw this old, black car and immediately thought, 'Oh! John's here!'"

[John W.]

Another month & not a big update, but an important one. My sis & her boyfriend flew in from Germany and we rode motorcycles from St. Paul to Sturgis, SD, nearly 2000 miles total. We used the Falcon as the safety car for about 1/2 the trip - yes, the Falcon that I basically bought from jaws of the junkyard 4 months prior! And it did great! We only used the Falcon for 1/2 the trip, to & from Eastern South Dakota, mainly because of the brakes, power steering, AC, etc. We borrowed my brother's Flex for the trip to & from the Black Hills. I'm losing some brake fluid out the back reservoir, but I'm thinking seriously of converting to power disc brakes + a drum 8" rear axle over the winter. I have some serious concerns the little 7.5" is going to handle the 2.3T!

That's it for now. Will keep you posted.

[turbo970]

Originally posted by John W.:
"That rug really tied the room together, man."

:thumbup: I dig that sticker - dude. Very fitting

sweet project, I wouldn't mind finding one of these some day. nothing better than a reliable old car IMO

[John W.]

Well, I put in my order for front disc brakes and an 8" "Cougar" rear axle to convert to legit running gear. I figure I might as well replace the old shocks & suspension bushings while I"m at it.

Still searching for a ready-and-willing flex plate & cover for the 2.3L so I can bench-test. I know where there sits a complete mid-80's Ranger 2.3L but he's hesitant to part it out for the few things I need.