DOHC engine replacement - Taurus Car Club of America : Ford Taurus Forum
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post #1 of 24 (permalink) Old 08-13-2019, 03:36 PM Thread Starter
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Join Date: Jun 2010
Location: Minnesota
Chapter: Midwest
Year: 2004
Model: Mercury Sable
Engine: 3.0L 24v Duratec V6
Posts: 462
Rep Power: 19
 
Trader Score: 1 reviews
DOHC engine replacement

I recently replaced the engine in my '02 SES DOHC and since I was documenting the process anyway thought I would post it here if it would help anyone else along the way.


Backstory - I bought this car about a year ago for $500. The previous owner took great care of it but said the transmission was 'blown' and was told by a mechanic it wasn't worth fixing. With just over 100K on the clock and basically rust free I thought it was worth the gamble to fix/replace the transmission. Turns out it was the common torque converter splines stripped out so I repaired that and it became my sons new college car. A few months ago while I was out of town my son calls and said the oil light was coming on intermittently but had checked the oil level and all was good. This being the 'bullet-proof' Duratec I thought it must be the oil pressure sending unit and told him to keep driving and I would fix it when I got home. 10 minutes later he called that the engine locked up and had left a trail of oil behind him. I hated to scrap an otherwise good car so decided to replace the engine. (spoiler - it's now my daily driver so the transplant worked!)
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Kevin

Current stable
2004 Sable LS Prem DOHC
2003 Taurus SES Vulcan
2002 Taurus SES DOHC

Retired:
2001 Taurus SES DOHC
2000 Taurus SE Vulcan
1994 Sable GS
1988 Taurus LX

Last edited by Hornswaggle; 08-13-2019 at 03:43 PM.
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post #2 of 24 (permalink) Old 08-13-2019, 03:51 PM Thread Starter
Member
 
Join Date: Jun 2010
Location: Minnesota
Chapter: Midwest
Year: 2004
Model: Mercury Sable
Engine: 3.0L 24v Duratec V6
Posts: 462
Rep Power: 19
 
Trader Score: 1 reviews
I started by dropping the exhaust y-pipe and dropping the oil pan and windage tray. This is how that looked, notice the hole in the oil pan made by the connecting rod and all the shrapnel in the bottom of the pan
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Kevin

Current stable
2004 Sable LS Prem DOHC
2003 Taurus SES Vulcan
2002 Taurus SES DOHC

Retired:
2001 Taurus SES DOHC
2000 Taurus SE Vulcan
1994 Sable GS
1988 Taurus LX
Hornswaggle is online now  
post #3 of 24 (permalink) Old 08-13-2019, 03:53 PM Thread Starter
Member
 
Join Date: Jun 2010
Location: Minnesota
Chapter: Midwest
Year: 2004
Model: Mercury Sable
Engine: 3.0L 24v Duratec V6
Posts: 462
Rep Power: 19
 
Trader Score: 1 reviews
next came the windage tray, this is exactly as it came out with chunks of piston on top
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Kevin

Current stable
2004 Sable LS Prem DOHC
2003 Taurus SES Vulcan
2002 Taurus SES DOHC

Retired:
2001 Taurus SES DOHC
2000 Taurus SE Vulcan
1994 Sable GS
1988 Taurus LX
Hornswaggle is online now  
 
post #4 of 24 (permalink) Old 08-13-2019, 03:58 PM Thread Starter
Member
 
Join Date: Jun 2010
Location: Minnesota
Chapter: Midwest
Year: 2004
Model: Mercury Sable
Engine: 3.0L 24v Duratec V6
Posts: 462
Rep Power: 19
 
Trader Score: 1 reviews
Here you can see what's left of the connecting rod and piston. I believe this would be cyl#6, front bank cyl nearest the battery.
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Kevin

Current stable
2004 Sable LS Prem DOHC
2003 Taurus SES Vulcan
2002 Taurus SES DOHC

Retired:
2001 Taurus SES DOHC
2000 Taurus SE Vulcan
1994 Sable GS
1988 Taurus LX
Hornswaggle is online now  
post #5 of 24 (permalink) Old 08-13-2019, 04:04 PM Thread Starter
Member
 
Join Date: Jun 2010
Location: Minnesota
Chapter: Midwest
Year: 2004
Model: Mercury Sable
Engine: 3.0L 24v Duratec V6
Posts: 462
Rep Power: 19
 
Trader Score: 1 reviews
I located a donor engine on car-part.com at a nearby salvage yard. Here's a pic of the car it came out of, only 94K miles!
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Kevin

Current stable
2004 Sable LS Prem DOHC
2003 Taurus SES Vulcan
2002 Taurus SES DOHC

Retired:
2001 Taurus SES DOHC
2000 Taurus SE Vulcan
1994 Sable GS
1988 Taurus LX
Hornswaggle is online now  
post #6 of 24 (permalink) Old 08-13-2019, 04:07 PM Thread Starter
Member
 
Join Date: Jun 2010
Location: Minnesota
Chapter: Midwest
Year: 2004
Model: Mercury Sable
Engine: 3.0L 24v Duratec V6
Posts: 462
Rep Power: 19
 
Trader Score: 1 reviews
Next came getting the old engine ready to come out. Disconnect all the wiring, vacuum lines, accessories such as a/c, alt, ps, cooling, etc. My plan was to drop the complete power unit on the subframe so transmission had to be ready to go too.
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Kevin

Current stable
2004 Sable LS Prem DOHC
2003 Taurus SES Vulcan
2002 Taurus SES DOHC

Retired:
2001 Taurus SES DOHC
2000 Taurus SE Vulcan
1994 Sable GS
1988 Taurus LX
Hornswaggle is online now  
post #7 of 24 (permalink) Old 08-13-2019, 04:11 PM Thread Starter
Member
 
Join Date: Jun 2010
Location: Minnesota
Chapter: Midwest
Year: 2004
Model: Mercury Sable
Engine: 3.0L 24v Duratec V6
Posts: 462
Rep Power: 19
 
Trader Score: 1 reviews
Next, I decided to pull the entire front suspension to make it easier to maneuver since I was working alone. I've seen some people leave the struts in place but for me it made more sense to just remove anything that could get in the way, especially during reinstallation.
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Kevin

Current stable
2004 Sable LS Prem DOHC
2003 Taurus SES Vulcan
2002 Taurus SES DOHC

Retired:
2001 Taurus SES DOHC
2000 Taurus SE Vulcan
1994 Sable GS
1988 Taurus LX
Hornswaggle is online now  
post #8 of 24 (permalink) Old 08-13-2019, 04:15 PM Thread Starter
Member
 
Join Date: Jun 2010
Location: Minnesota
Chapter: Midwest
Year: 2004
Model: Mercury Sable
Engine: 3.0L 24v Duratec V6
Posts: 462
Rep Power: 19
 
Trader Score: 1 reviews
next came attaching an engine crane. my plan was to lower the unit by attaching chains to the four corners of the subframe for best support and this worked very well.
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Kevin

Current stable
2004 Sable LS Prem DOHC
2003 Taurus SES Vulcan
2002 Taurus SES DOHC

Retired:
2001 Taurus SES DOHC
2000 Taurus SE Vulcan
1994 Sable GS
1988 Taurus LX
Hornswaggle is online now  
post #9 of 24 (permalink) Old 08-13-2019, 04:21 PM Thread Starter
Member
 
Join Date: Jun 2010
Location: Minnesota
Chapter: Midwest
Year: 2004
Model: Mercury Sable
Engine: 3.0L 24v Duratec V6
Posts: 462
Rep Power: 19
 
Trader Score: 1 reviews
Here you can see how it was chained to the subframe and lowered on to a couple moving carts. You may notice that the power streering line normally goes on the inside of the subframe so I had to separate the subframe from the transmission mount temporarily so I could slip the hydraulic line outside.
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Kevin

Current stable
2004 Sable LS Prem DOHC
2003 Taurus SES Vulcan
2002 Taurus SES DOHC

Retired:
2001 Taurus SES DOHC
2000 Taurus SE Vulcan
1994 Sable GS
1988 Taurus LX
Hornswaggle is online now  
post #10 of 24 (permalink) Old 08-13-2019, 04:23 PM Thread Starter
Member
 
Join Date: Jun 2010
Location: Minnesota
Chapter: Midwest
Year: 2004
Model: Mercury Sable
Engine: 3.0L 24v Duratec V6
Posts: 462
Rep Power: 19
 
Trader Score: 1 reviews
and the engine is out! with the car on tall jack stands the engine was able to roll out the passenger wheel opening on the moving carts.
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Kevin

Current stable
2004 Sable LS Prem DOHC
2003 Taurus SES Vulcan
2002 Taurus SES DOHC

Retired:
2001 Taurus SES DOHC
2000 Taurus SE Vulcan
1994 Sable GS
1988 Taurus LX
Hornswaggle is online now  
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