19 January, 2015

2004 Ford F150 5.4L DTC 0016 and 0012 fix.

So my truck threw a couple of codes and started running something awful, I could have used my general purpose code scanner dongle my wife got me for Christmas a couple of years ago, but instead I grabbed by SCT XCal 2 and pulled the codes. P0016 and P0012. Both for bank #1.

Did some quick Googling, and found those codes refere to the VCT solenoid. For those that don't know, VCT means Variable Cam Timing, and is a HUGE part of why modern engines produce so much more horsepower compared to older engines, for the same or better mileage and emissions...

The truck ran, rough, but it ran, so I went ahead and ordered the parts I needed, figuring I had all the correct tools. I was WRONG!

For my issue, the positive is that the error / code threw in relation to bank 1, the passengers side of the truck, which is easier to get to. The bad side, and something I was unaware of when I started this project, is that there is a T-25 Torx fastener in a what the heck were they thinking location...

To get the job done, I needed the following tools...

#1. Rubber / acid resistant glove.
#2. 8mm box end wrench.
#3. Screwdriver set with several flat blade screwdrivers.
#4. Long nose Vise Grip pliers.
#5. T25 Torx screwdriver with a shaft about .25" longer than the one I used. More on that later...
#6. Chunk of scrap 3/4" plywood approximately 2" wide and 10" long.
#7. Soft face mallet.

For supplies, you will need the solenoid itself, as well as a new VCT Solenoid Grommet. After my experience with the aftermarket solenoid, I also HIGHLY recommend ether a very certain and steady hand, OR some brake cleaner and a drop of good some kind of oil resistant stickum to absolutely insure the screw stays attached to the screwdriver until you have it fully seated and retract the screwdriver, OR, and this is a last resort, a good quality long reach mechanics retrieval magnet.

I used the Dorman 917-200 Variable Valve Timing Solenoid which is a direct replacement for the Ford OEM unit, incorporates some design fixes, but has the unfortunate design flaw of NOT being built to hold the retaining screw fully captive. This is only a problem during assembly and disassembly. I managed somewhat white knuckled, but I got it done...

The procedure sounds very simple for this side on paper...

Step..
#1. Protect ground battery terminal with acid resistant glove and loosen positive with 8mm box wrench, remove positive battery cable.
#2. Disconnect wiring harness lead from VCT solenoid by depressing on the release tab, it is oriented if you are staring at the valve cover from over the passengers side fender, at the approximmately 7:00 position.
#3. Remove the VCT Solenoid grommet by gripping it with pliers and pulling it free.
#4. Loosen the T25 screw from the VCT solenoid that is at about 2:00 position, and draw the solenoid free from the cylinder head.
#5. Remove the captive screw from the freshly removed VCT Solenoid.

Assembly is allegedly the reverse of disassembly.

That is NOT how it worked...

I got as far as starting to remove the VCT Solenoid grommet...

100K + miles and the Texas heat made the original piece somewhat less than cooperative coming out.... I figured the method out and it is thus...

#1. Soak the area around the grommet with a good penetrating oil like Aerokroil or better.
#2. Remove the valve cover oil filler cap.
#3. Pry up on the exposed lip / tab along the top of the grommet with a slim enough to fit under, but sturdy enough to pry with flat blade screwdriver once you have worked it up far enough, grasp it firmly with the Vise Grips.
#4. Working your way around from the flared piece pry up using that flat blade screwdriver, counter clockwise, occasionally tugging on the locked on vise grips...
#5. After a considerable amount of time, effort, and possibly colorful language, you hit a "sweet spot' where the grommet just sort of lets go and comes off...

Removal of the Torx screw was far less than simple as well... For starters, my existing Torx screwdriver set went up to T20, where my Torx sockets started at T30, leaving the all too uncommon, and critical T25 gap that we need for our project...

I was pressed for time, so online ordering the right tool wasn't ever really an option. So I went to Advance Auto and picked up a T25 socket, thinking this should do the trick...

No joy. The T25 socket, being 3/8 drive is simply too big to fit in the cylinder head service port for the VCT solenoid...

I ended up running back to Advance needing to buy a T25 screwdriver. They did not have just a single solitary T25 driver, no... it had to be part of a set....

So in desparation I bought the set, and went back to work, only to find out the T25 driver is just a shave too short to get into the T25 bolt fully seated with the shaft of the screwdriver dead straight, the handle hits the top of the VCT solenoid somewhat. With this being such a miserable failure, I am seriously wishing I had a longer shaft T25 screwdriver, had I known that the driver I had was insufficient I would have ordered one like the SK tools Torx Screwdriver T-25 5.91In. Suregrip which would have afforded me greater peace of mine in reassembly with that screw not fully captured...

Installation was indeed reverse of removal, with the added fun of making DANG sure the screw did NOT get loose from the new solenoid as I reinstalled it.

Now I have it reinstalled, code cleared, and a smooth running V8 engine again. Hopefully this means I can get some gas mileage back. The dumb thing was getting down to single digits. Low gas prices are nice and all, but I HATE wasting gas....

14 January, 2015

Giving up your excess could be the answer to somebodies prayers...

Now I've known, and seen folks that pretty much hold on to any, and every last little trinket that they get their hands on... And while I have my shop, and home, well stocked, we often go through and determine what is just sucking up space and cluttering up our lives. 

Sometimes, we sell, but sometimes, it is just easier and more beneficial to find a non profit organization that can make use of my excess to further their cause...

In my recent case of the clean out / donation cycle, I have come across surplus musical equipment, and tools. Specifically my old B&D Firestorm non slide 10" miter saw needed to go. I had the Chicago Electric 12" slider set up well, and was happy with it, and the old B&D was sucking up space in my shop. I've got a friend and neighbor that is a dad with very young kids, that while he's not broke by any means, needs to be careful with his family funds, and needed to replace a broken older Delta miter saw... So out the door of my place over to his the B&D went. It will live on now to help him finish the crown molding project he started on that managed to kill his 20+ year old Delta...

The musical gear I had in excess was a nearly new 100 watt 1x15 bass amp. I had it listed on bass players forums for sale, on Craigslist, and several other locations... No bites. Price was listed reasonably, but no interest. Admittedly I did wait until I got my own new amp to sell this one, so the purchase for Christmas stuff was over... But it was a good amp, and it needed a home that could use it...

A few phone calls and I got in touch with the worship leader at my church, who was more than happy to take the donation in. When I dropped it off, he mentioned that the amp in the high school area was on its last legs and this was a real answer to prayer as they needed a new one...

So now I have less junk cluttering up my life, and even though I didn't get any cash value back from any of this, I DID get satisfaction knowing that my donations are making a difference in the lives of folks around me... And that can be worth far more than money...

I will admit, the bass amp at least going to a non profit organization, can be written off my 2015 income taxes, so I guess there is a financial benefit to me, not much of one, but I will take it. Takes over the last several years have been kind of painful. Any relief is a blessing...

If you've got stuff cluttering up your life, and assuming you don't need to sell it to raise money, you might want to seriously consider donation to a worthy cause. You just might make a difference in peoples lives!

05 January, 2015

Holidays are done, time to get back into the shop!

First off, Happy New Year, and welcome to 2015!

I must apologize for being away so long, I have had a complicated couple of months, but basically my lovely bride has been working me to death over the holiday season decorating this that at the other thing, testing and fixing light strings, putting up the tree, blah blah blah... You get the idea... And on top of that, I have been dealing with some health setbacks. It would appear that the flu shot that went out this year was worthless for me, and I managed to aggravate existing back issues. So I have spent time healing, and honestly, I kind of let things slip my mind...

Now that the new year is here, and I am feeling MUCH better, it is time for me to get back into the shop and get some things done...

An overdue gift to my wife is refinished kitchen cabinets. I am hand sanding down the original doors, and door frames, easier said that done... The profile detail of the originals is a real son of a gun to sand without killing the profile...

I started out the process by using Citrustrip. and maybe I misread the instructions, but it DID say to rinse the stripper off, BAD idea. I ended up with warped wood, and delaminated plywood panels. Good thing the new owner of the home 2 houses down was replacing the cabinets with new units. He was kind enough to give me a couple of the doors from his cabinets that matched mine to replace the doors too far gone to fix...

So in lieu of stripper, I am now manually sanding, a time intensive operation. But it IS going well...

I have all but two of the doors from the overhead section completed, one just needs a fine sanding, the other the detail areas need to be sanded and then the whole thing needs to be fine sanded, then it's cleaning / dust removal, and stain / poly coats for these doors!

Once the doors are done, I move into the kitchen and sand those face frames, those should go fast, and then stain, poly, and finally, attach the new soft close hardware and doors, then move to the lower cabinets...

I think I FINALLY found my leak. It appears the faucet sprayer from the kitchen sink has been leaking, which saturated the particle board base of the cabinet. I will have to cut out that piece, make and install some cleats for a new panel to sit on, and then cut / fit the new panel in 2 pieces and attach. Will pre-paint it and make certain that it is sealed... Will be using 1/2" ply for the panel, and 3/4x3/4 stock for the cleats. Going to go all Norm Abram on these and attach it with glue and brads...

Time away from the shop has been well spent though. I have picked my bass guitar back up and been playing / practicing, and realizing I set that down too long, so I am going over the educational material I used before, I had to order one of the videos in a new copy on DVD as I no longer have a VHS VCR to play back the old tapes... But I am coming back pretty fast. Doing a lot of slow ballads, and quarter note stuff. It's coming along nicely.

For my back sake, I did ask for a new amp instead of tools this year, and I replaced my old Crate BX100 amp (67 lbs) with a new Fender Rumble V3 500 combo amp (36.5 lbs). My back is MUCH happier with me now!