Piston: Service and Repair
DISASSEMBLYNOTE: Any piston rings that are removed from piston should be discarded and replaced with new rings.
1. If piston ring replacement is required, use a suitable piston ring expander to remove two compression rings. Remove two oil ring rails and expander by hand.
WARNING: Cover the end of the pin bore with a hand or shop rag when removing the retainer ring since it has a tendency to spring out. Eye protection should be worn.
2. Using O-Ring Tool T71P-19703-C, remove the two piston pin retaining rings.
3. Gradually heat the piston to approximately 100°C (21°F).
NOTE: The piston and piston pin (6135) are a matched set. Keep pistons, piston pins, rings, connecting rods and connecting rod bearings together in proper cylinder order.
4. Using Piston Pin Tool D81L-6135-A or equivalent, press piston pin from piston and connecting rod.
REASSEMBLY
NOTE: Prior to service re-installation or replacement of fasteners, all threads and contact surfaces must be lubricated with clean engine oil meeting Ford specification WSS-M2C153-F.
1. Coat piston bores, piston and rings, crankshaft journal and bearing surfaces with clean engine oil meeting Ford specification WSS-M2C153-F.
2. Verify that all parts to be assembled are for same cylinder. Assemble piston to connecting rod.
3. Install a new retainer ring on one side of the piston pin bore.
4. Gradually heat piston to approximately 100°C (212°F).
5. Start piston pin in piston and connecting rod immediately after heating piston. This may require a very light tap with a mallet.
6. Using Piston Pin Remover and Replacer D81L-6135-A or equivalent press piston pin through piston until piston pin bottoms on retainer ring.
7. Install a new retainer ring on other side of the piston pin bore.
8. After assembly, make sure connecting rod swings smoothly.
9. If removed, install piston rings. Follow proper procedure.
10. Install piston and piston rings with notch on piston pointing to the front of engine.