2005 4WD 2500 Engine Removal

[JMumbauer]

I'm in the middle of an engine removal on a 2005 pickup which had a catastophic connecting rod failure. I've got everything removed with the upper core support out, but there's not enough room to fit the engine between the cowl and the lower radiator support while still clearing the oil pan on bottom! Even with the balancer, tensioner, and lower fan shroud support removed I'm still lacking a couple inches.



I tried to remove the lower radiator support by removing the bolts and trying to slide out the side, but it simply wont slide that far to slip out. What am I doing wrong? Pics would probably be helpful so I'll try to load some up tonight or tomorrow...



Thanks!



-Jake

 

[rscurtis]

Hopefully I'll never have to do this, but others have indicated that if you remove the bolts that secure the front of the fenders, thay can be spread far enough to remove that crossmember.

 

[sag2]

Carefully spread the fenders and it will slip out. Otherwise the FSM says to cut it at a diagonal and weld a patch to join it back together. Much less trouble to spread the fenders.

 

[JMumbauer]

Thanks for the feedback; I was able to adjust the chain hoist lifting point to help angle the engine, remove #6 injector line, fuel return line and a bracket on the back of the head, then carefully slide it out. (took several tries resetting the engine and re-hooking) Talk about a pain in the butt. I will try use this process only reversed for reassembly, but may wind up cutting and welding that front crossmember.



-Jake

 

[Shadrach]

I used a port a power to spread the fenders apart and tilted the engine nose down using a screw type lifting slingin order for the pan to clear the crossmember. I also took the valve cover off. When my engine was rebuilt and all painted up I had the valve cover on and it made it a bit more difficult. I ripped my firewall insulation a bit. I left the mounts in the chassis until the engine was out and then took them out. I put the engine in first then the mounts. DON'T mix them up side to side ( ask me how I know Shadrach