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    03 5.4L 2V - new oil pump won't prime

    I just completed reassembling the motor after doing the head gaskets. I followed FordTechMakeuloco's procedure for priming the pump (crank motor with crankshaft position sensor unplugged until pressure guage shows pressure). I did this several times with no change to the pressure guage. There...
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    2003 5.4L - Radiator leaking after reassembly

    Many thanks!
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    2003 5.4L - Radiator leaking after reassembly

    I hope that this is the last mishap that I need to share with you all. After the head gasket job, I had the whole motor reassembled. Today I poured in a gallon of antifreeze and it immediately leaked out of the bottom of the radiator, where the two tranny lines enter it. When I originally...
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    2003 5.4L - Baffled by power steering hose

    Thanks very much for the input and the photo. Go figure, I ended up having to replace the line. No problem now. I must have bent it, even though I was unaware.
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    2003 5.4L - Baffled by power steering hose

    I hesitate to post this because of the low probability that this problem will translate well into a forum post. But I'm at the end of my rope with this, and it's the only issue standing in the way of me completing reassembly after a head gasket repair. I removed the PS pump and pressure line...
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    Overtorqued Head Bolts

    Thanks to both of you for sharing your thoughts. I will get new bolts. Thankfully, this was the first of the two heads that went in and I hadn't assembled any other parts. I'll also lay a straight edge across the deck to see if I warped my beautiful newly resurfaced head, argh.
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    03 5.4L (2 valve) head gasket replacement - parts list

    The sprockets came with the timing kit (this kit was a mere $6 more than the one without sprockets, strangely). At the time I placed the order, I had not noticed that my camshafts are the type you describe, where the sprockets can't be removed. I figured (incorrectly) I would replace the...
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    Overtorqued Head Bolts

    I woke up at 2am this morning and realized that I had made this ridiculous mistake when working on my 03 5.4 yesterday. For the second and third stages of torqueing, I torqued 180 degrees per turn instead of 90. Can't believe I did that. But, what's done is done. I'm going to pull the head, and...
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    03 5.4L (2 valve) head gasket replacement - parts list

    I have looked at many of the usual sites (Rock Auto, Amazon, Ebay, etc.) and cannot find the hose that connects the expansion tank to the block. Anybody know where to find it? Thanks.
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    03 5.4L (2 valve) head gasket replacement - parts list

    Funny you should mention this. I went ahead and used the puller. This particular pulley was very, very stubborn. The adapter lug got stuck in the pulley during attempted removal of the pulley and the main removal shaft on the tool got bent. I ended up having to remove the pump and hose, take it...
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    03 5.4L (2 valve) head gasket replacement - Disassembly questions

    Hamfisted, just wondering if you bolted on the exhaust manifolds before dropping the heads in. Seems like the easiest way to go...from my vantage point of limited knowledge.
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    03 5.4L (2 valve) head gasket replacement - parts list

    Ok, I think I can answer my own question, after looking at some aftermarket camshafts. It appears that on aftermarket camshafts, the part of the camshaft where the sprocket is mounted is much wider than the original camshaft, which is why these sprockets that I bought look the way they do.
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    03 5.4L (2 valve) head gasket replacement - parts list

    I ordered this Melling timing set (Part Number: 5252-07536389) which included two new camshaft sprockets. These sprockets are clearly designed for a camshaft of much greater diameter than the ones in my vehicle, which is weird because this is definitely the right set for my 2003. Just wondering...
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    03 5.4L (2 valve) head gasket replacement - Disassembly questions

    Excellent suggestion. I will call them, although I assume they will do this as they return the heads looking like new. Thanks.
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    03 5.4L (2 valve) head gasket replacement - Disassembly questions

    Thanks for the advice and Hamfisted and BlackCoffee. I ordered those heads online with hesitation, as Clearwater is a large operation which I know could mean quality control issues. So I ended up cancelling the order. I'm going to take the heads to a reputable machine shop in the next county...
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    03 5.4L (2 valve) head gasket replacement - Disassembly questions

    Yes, it was a blown head gasket. After mulling this over, I decided to buy two reconditioned heads from these guys: https://www.cylinder-heads.com/ $355/head Complete and ready to install 5-year warranty Surprisingly, it doesn't matter what condition your cores are in. No matter what, they will...
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    03 5.4L (2 valve) head gasket replacement - Disassembly questions

    Finally got the heads off. Fortunately for my lower back, they weren't as heavy as I thought they would be. Driver's side came off no problem. Passenger side was a bit ugly. I pulled a rookie maneuver and forgot to remove the bolts (fastening the braided ground wire and coolant tube bracket)...
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    03 5.4L (2 valve) head gasket replacement - Disassembly questions

    Thank you. Will do on the oil tube. Removing the tranny bracket bolt was what finally allowed me to get the valve cover off. Now, all I need is for my lower back to not give out when I pull the heads today!
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    03 5.4L (2 valve) head gasket replacement - Disassembly questions

    I'll (finally!) pull both heads off tomorrow. As I was wrapping up, I realized that I would need to completely remove the oil dipstick tube before pulling the driver's side head, because it snakes down between the manifold and the head. Just to confirm: to remove the oil dipstick tube you just...
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    03 5.4L (2 valve) head gasket replacement - Disassembly questions

    Thanks Hamfisted and Vincent Vega for the input. I actually removed both heater hoses and have all other hoses and wires tucked well out of the way. I was wondering about that tranny dipstick tube. I am going to unbolt it and hopefully I can then shimmy the cover by those AC tubes. The...
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    03 5.4L (2 valve) head gasket replacement - Disassembly questions

    What is the secret to pulling off the passenger side valve cover? It seems to me that the two metal AC lines coming out of the bulkhead won't allow me to lift the cover high enough to clear the camshaft. I've been at it for some time with no luck. Any suggestions?
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    03 5.4L (2 valve) head gasket replacement - Disassembly questions

    Thanks very much for the input. So I called the local shop again just to confirm their pricing and was happy to hear that to "deck the head" (machine the mating surface) is only $85/head. Obviously, I will get this done. The $425/head is a complete head reconditioning, with valve job.
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    03 5.4L (2 valve) head gasket replacement - Disassembly questions

    I have assumed from the start that I was going to have the heads done at the local machine shop or order reconditioned heads. That is what I have done in the past. Now, as the price tag for this repair continues to grow, I am wondering if having the heads machined is even necessary. The local...
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    03 5.4L (2 valve) head gasket replacement - parts list

    Thank you!!!
  25. E

    03 5.4L (2 valve) head gasket replacement - parts list

    I understand what this tool does, but I'm not sure if I will need just one or two of them. I'm guessing two as both camshafts will need to be immobilized at the same time, right? Thanks again.

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