Crankshaft R&R

Complete removal and replacement of the crankshaft, requiring engine removal from vehicle, full disassembly of rotating assembly, inspection of all bearing surfaces, and complete rebuild with new bearings and seals.

Warnings

Tools required

Parts

• Main bearing set (standard or oversize as needed) × 1 — Use OEM specification or Federal Mogul MS-909P
• Connecting rod bearing set (standard or oversize as needed) × 1 — Use OEM specification or Federal Mogul MS-1090P
• Thrust bearing set × 1 — Use OEM specification
• Front crankshaft seal × 1 — Use OEM specification
• Rear main seal (2-piece rope or neoprene) × 1 — Use OEM specification
• Oil pan gasket set × 1 — Fel-Pro OS30011R or equivalent
• Timing cover gasket × 1 — Use OEM specification
• Timing chain and sprocket set × 1 — Use OEM specification or Cloyes C-3003
• Oil pump × 1 — Use OEM specification or Melling M55
• Oil pump pickup tube O-ring × 1 — Use OEM specification
• Harmonic balancer bolt × 1 — Use OEM specification
• Flywheel/flexplate bolts × 6 — Use OEM specification
• Main cap bolts (if replacing) × 10 — Use OEM specification
• Connecting rod bolts (if replacing) × 16 — Use OEM specification
• Intake manifold gasket set × 1 — Fel-Pro MS90003 or equivalent
• Exhaust manifold gaskets × 2 — Fel-Pro MS93245 or equivalent
• Valve cover gaskets × 2 — Fel-Pro VS12851T or equivalent
• Water pump gasket × 1 — Use OEM specification
• Thermostat and gasket × 1 — Use OEM specification
• Engine oil filter × 1 — Use OEM specification or AC PF25

Fluids

• 5W-30 Conventional engine oil — 5 qt
• DEX-COOL Extended Life coolant — 10 qt

Preparation

1. Park vehicle on level surface and engage parking brake. Place wheel chocks behind rear wheels.
2. Disconnect negative battery cable and remove battery from vehicle.
3. Drain engine oil completely into appropriate container and drain coolant from radiator and block into separate container.
4. Remove hood and store safely to provide access to engine bay. Mark hood hinge positions before removal.
5. Remove air cleaner assembly and disconnect all vacuum lines, labeling each for reassembly.
6. Disconnect fuel line at fuel pump (be prepared for residual fuel spillage).
7. Remove radiator upper and lower hoses, heater hoses, and radiator shroud. Remove radiator assembly.
8. Label and disconnect all electrical connections including alternator, starter, temperature sender, oil pressure sender, and distributor.
9. Remove distributor cap with plug wires attached and set aside. Mark distributor position and remove distributor.
10. Disconnect throttle linkage and remove carburetor or fuel system components as needed.
11. Disconnect exhaust pipes at manifolds (penetrating oil recommended for exhaust fasteners).
12. Remove engine mount through-bolts on both sides.
13. If manual transmission: disconnect clutch linkage and remove bellhousing bolts. If automatic: mark flexplate-to-torque converter relationship and remove converter-to-flexplate bolts.
14. Support transmission with jack and remove transmission-to-engine mounting bolts.
15. Attach engine hoist securely to lifting points on engine (intake manifold bolts or dedicated lifting brackets).
16. Verify all connections, hoses, and wiring are disconnected before lifting.
17. Carefully lift engine while guiding it away from transmission input shaft (manual) or torque converter (automatic). Angle engine as needed to clear firewall and remove from vehicle.
18. Mount engine securely on engine stand using bellhousing bolt holes.

Procedure

1. 1

   Remove external engine components
   Remove alternator, power steering pump (if equipped), and mounting brackets. Remove water pump and thermostat housing. Remove fuel pump and pushrod. Remove valve covers and set aside. Remove intake manifold with carburetor attached, removing all fasteners and lifting straight up to avoid damaging gasket surfaces. Remove exhaust manifolds if still attached. Remove harmonic balancer using puller tool - do not hammer on balancer as this will damage crankshaft.
2. 2

   Remove timing cover and timing components
   Remove the timing cover bolts and carefully pry timing cover off. Remove timing chain tensioner if equipped. Using a puller or gentle prying, remove the timing chain and both sprockets (crankshaft and camshaft). Note the alignment marks on sprockets for reassembly reference. Remove camshaft thrust button from front of camshaft.
3. 3

   Remove oil pan and oil pump
   With engine inverted on stand if possible, remove all oil pan bolts. Carefully separate oil pan from block using a gasket scraper or plastic mallet - do not pry against gasket surfaces. Remove oil pump mounting bolt and remove oil pump with pickup tube assembly. Inspect oil pump pickup screen for debris.
4. 4

   Remove flywheel or flexplate
   Lock flywheel/flexplate using holding tool. Remove the 6 flywheel/flexplate mounting bolts and remove flywheel or flexplate from crankshaft flange. Inspect flywheel surface for cracks or hot spots; resurface or replace if damaged.
5. 5

   Remove pistons and connecting rod assemblies
   Rotate crankshaft to position cylinder 1 at bottom dead center. Using a permanent marker, mark each connecting rod and cap with cylinder number and orientation (mark one side only, facing same direction). Check for ridge at top of cylinder bore - remove with ridge reamer if present to prevent ring damage during piston removal. Remove connecting rod cap bolts (2 per rod, 8 connecting rods total). Remove each rod cap and keep matched with its rod. Push each piston/rod assembly up and out through top of cylinder, being careful not to damage crankshaft journals with rod bolts (cover rod bolts with rubber hose or protectors). Keep each piston/rod assembly organized by cylinder number.
6. 6

   Remove main bearing caps and crankshaft
   Verify all main bearing caps are marked with position numbers (1 through 5, front to rear) and orientation arrows. If not marked, use a center punch to mark each cap and its corresponding location on the block before removal. Remove the 2 bolts from each of the 5 main bearing caps. Carefully remove each main cap using gentle prying or a puller tool - do not use excessive force as caps can be brittle. Remove the thrust bearing halves from the number 5 main bearing position (rearmost). With all caps removed, carefully lift crankshaft straight up and out of the block. Set crankshaft on clean work surface padded with shop rags to protect journals.
7. 7

   Inspect block and crankshaft
   Remove all bearing inserts from main saddles and connecting rods. Thoroughly clean all bearing surfaces in block and caps using solvent and clean rags. Inspect block main bearing saddles for scoring, cracks, or damage. Using a dial bore gauge, measure each main bearing bore diameter at multiple points and compare to specification (should be approximately 2.7484-2.7494 inches for standard 327). Clean crankshaft thoroughly with solvent, paying special attention to oil passages - use rifle brush to clean oil holes. Inspect all crankshaft journals for scoring, heat discoloration, or taper. Using a micrometer, measure all 5 main journals and all 8 connecting rod journals at multiple points. Main journal standard diameter is 2.2988-2.2998 inches; rod journal standard diameter is 2.0988-2.0998 inches. Record all measurements. If any journal is more than 0.001 inch out of round or tapered, or shows scoring, crankshaft must be ground to next undersize (0.010, 0.020, or 0.030 inch undersize). Check crankshaft end play specification - thrust surfaces should show minimal wear.
8. 8

   Install main bearings and prepare for crankshaft installation
   Ensure all bearing surfaces in block and caps are perfectly clean and dry. Install new main bearing inserts into block saddles, ensuring bearing tang engages notch in saddle. Install corresponding bearing inserts into main caps, again ensuring proper tang engagement. Apply assembly lube liberally to all bearing surfaces. Install thrust bearing halves in the number 5 main position (upper and lower), with oil grooves facing outward. Do not apply sealant to bearing backs - they must be dry for proper crush fit.
9. 9

   Install crankshaft and main caps
   Carefully lower crankshaft into block, seating it gently into the prepared main bearings. Verify crankshaft rotates freely by hand. Apply assembly lube to main cap bearing surfaces. Install each main bearing cap in correct position and orientation, ensuring cap numbers and orientation marks align with block markings. Hand-thread all main cap bolts. Following the sequence from center (cap 3) outward (cap 2, cap 4, cap 1, cap 5), tighten main cap bolts in stages. First pass: snug all bolts. Second pass: torque all bolts to 35 ft-lb. Third pass: torque all bolts to 70 ft-lb. Final pass: torque all bolts to factory specification. After torquing, verify crankshaft rotates smoothly by hand - if binding occurs, disassemble and inspect for debris or bearing misalignment.
10. 10

    Verify bearing clearances with Plastigage
    Remove one main cap at a time. Place a strip of Plastigage across the bearing journal parallel to crankshaft centerline. Reinstall cap and torque to specification. Remove cap without rotating crankshaft. Compare crushed Plastigage width to scale on package to determine clearance. Acceptable main bearing clearance is 0.0008-0.0020 inches for standard bearings. Repeat for all 5 main bearings. Record all clearances. If any clearance is out of specification, disassemble and install correct bearing size. Remove all Plastigage residue completely before final assembly.
11. 11

    Check crankshaft end play
    Mount dial indicator against crankshaft nose. Using pry bars against crankshaft counterweights, pry crankshaft fully forward and zero dial indicator. Pry crankshaft fully rearward and record reading. Acceptable end play is 0.002-0.006 inches. If excessive, replace thrust bearings with thicker ones. If insufficient, inspect thrust bearing installation.
12. 12

    Install pistons and connecting rod assemblies
    Install new connecting rod bearing inserts in rods and caps, ensuring tang engages notch. Apply assembly lube to rod bearings and cylinder walls. Install ring compressor on piston 1, compressing rings fully. With notch or valve relief on piston crown facing front of engine, and rod orientation marks visible on correct side, carefully tap piston into cylinder 1 using hammer handle while guiding rod onto crankshaft journal. Remove rod bolt protectors. Install rod cap in correct orientation, matching cylinder number markings. Hand-thread rod bolts. Torque connecting rod bolts to factory specification. Repeat for all 8 pistons, ensuring each is installed in correct cylinder with proper orientation.
13. 13

    Verify rod bearing clearances
    Following same Plastigage procedure as main bearings, verify connecting rod bearing clearances. Remove one rod cap at a time, place Plastigage on journal, reinstall cap and torque to specification, remove cap and measure. Acceptable rod bearing clearance is 0.0007-0.0028 inches. Verify all 8 rod bearings are within specification. Clean all Plastigage residue completely.
14. 14

    Install rear main seal
    For 2-piece rope seal design: Press upper seal half into block groove using seal installation tool, allowing approximately 1/16 inch to protrude on each side. Press lower seal half into rear main cap groove, again allowing slight protrusion. Apply thin coat of RTV sealant to seal ends only. For 1-piece neoprene seal design: Install seal into rear main cap using seal driver, ensuring seal lips face forward toward engine. Apply thin coat of oil to seal lips.
15. 15

    Install oil pump and oil pan
    Prime oil pump by filling with assembly lube or fresh engine oil while rotating drive shaft. Install new pickup tube O-ring if applicable. Align oil pump driveshaft with distributor drive gear and install oil pump, torquing mounting bolt to specification. Apply thin bead of RTV sealant to oil pan rail and end seals. Install new oil pan gasket. Position oil pan on block and hand-thread all oil pan bolts. Torque oil pan bolts in spiral pattern from center outward to factory specification (typically 12-15 ft-lb).
16. 16

    Install timing components
    Install camshaft sprocket with timing mark facing outward. Install crankshaft sprocket with timing mark facing outward. Align both timing marks so they face each other and are on a centerline between cam and crank axes. Install timing chain over both sprockets. Install camshaft thrust button against camshaft with oiled side facing cam. Apply RTV sealant to timing cover gasket surfaces. Install new timing cover gasket and timing cover, ensuring oil slinger is in place behind harmonic balancer area. Install and torque timing cover bolts. Install front crankshaft seal using seal driver.
17. 17

    Install harmonic balancer
    Apply small amount of assembly lube to crankshaft snout and inside hub of harmonic balancer. Align balancer keyway with crankshaft key. Using harmonic balancer installation tool, press balancer onto crankshaft snout until fully seated against timing cover. Install new harmonic balancer bolt with thread locker. Torque harmonic balancer bolt to factory specification while preventing crankshaft rotation.
18. 18

    Install flywheel or flexplate
    Clean flywheel mounting flange on crankshaft and corresponding surface on flywheel/flexplate. Align flywheel/flexplate onto crankshaft flange, noting that bolt holes are unevenly spaced for correct orientation. Install 6 new flywheel bolts with thread locker applied. Using flywheel holding tool, torque bolts in star pattern to factory specification.
19. 19

    Install intake and exhaust manifolds
    Install new intake manifold gaskets, using alignment pins if provided. Apply RTV sealant to front and rear block rails where gaskets meet. Position intake manifold and hand-thread all bolts. Torque intake manifold bolts in proper sequence from center outward to factory specification (typically 25-35 ft-lb). Install new exhaust manifold gaskets. Install exhaust manifolds and torque bolts to specification (typically 25-30 ft-lb).
20. 20

    Install external components
    Install water pump with new gasket, torquing bolts to specification. Install thermostat and housing. Install valve covers with new gaskets. Install fuel pump with new gasket and ensure pushrod engages pump arm. Install alternator, power steering pump, and accessory brackets. Install distributor, aligning rotor to cylinder 1 firing position and ensuring oil pump drive engages.
21. 21

    Install engine in vehicle
    Attach engine hoist to lifting points and carefully lift engine from stand. Position engine in front of vehicle and guide into place, ensuring alignment with transmission. For manual transmission, align input shaft with pilot bearing and clutch disc. For automatic, align torque converter with flexplate. Install bellhousing or transmission-to-engine bolts and torque to specification. Install engine mount through-bolts and torque to specification. For automatic transmission, install torque converter-to-flexplate bolts according to alignment marks made during disassembly.
22. 22

    Reconnect all connections
    Reconnect exhaust pipes to manifolds with new gaskets if needed. Reconnect all electrical connections: alternator, starter, oil pressure sender, temperature sender, distributor. Reconnect throttle linkage. Reconnect fuel line to fuel pump. Install radiator assembly and reconnect all coolant hoses. Reconnect heater hoses. Reconnect all vacuum lines according to labels made during disassembly.
23. 23

    Fill fluids and perform initial start
    Install new oil filter. Fill engine with 5 quarts of 5W-30 conventional engine oil. Fill cooling system with 10 quarts of DEX-COOL coolant mixed 50/50 with distilled water. Reinstall battery and reconnect battery cables. Verify all tools and parts are clear of engine. Prime fuel system by operating manual choke or cranking engine briefly. Check initial timing setting. Start engine and verify oil pressure immediately (should show within 5-10 seconds). Allow engine to idle and warm to operating temperature while checking for leaks. Monitor temperature gauge during warm-up.

Reassembly

1. Torque all fasteners to factory specifications using proper sequence where applicable
2. Use new gaskets and seals throughout - do not reuse any gaskets
3. Apply thread locker to critical fasteners as specified (harmonic balancer bolt, flywheel bolts)
4. Verify all bearing clearances with Plastigage before final assembly
5. Lubricate all bearing surfaces with assembly lube, not engine oil
6. Follow timing marks precisely when installing timing chain
7. Ensure all main bearing caps and connecting rod caps are installed in correct positions with proper orientation
8. Double-check that no tools, rags, or parts remain in engine before closing

Verification

• Engine oil pressure should register within 5-10 seconds of starting and maintain minimum 10 psi at idle when warm, 30-40 psi at 2000 RPM
• Engine should idle smoothly with no unusual noises such as knocking, tapping, or grinding
• No oil leaks should be present at pan gasket, timing cover, valve covers, or rear main seal after warm-up
• No coolant leaks should be present at water pump, thermostat housing, or hoses
• Engine should reach normal operating temperature (160-195°F depending on thermostat) without overheating
• Verify proper ignition timing with timing light after warm-up
• Check crankcase for proper vacuum at PCV valve
• After initial 20-minute warm-up and cool-down, retorque cylinder heads if accessible, and recheck oil level
• Perform initial oil change after 500 miles and inspect filter for metal debris
• Listen for any abnormal noises during test drive under various loads

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