So, what started as a very noisy chain (with the tensioner fully extended) has evolved into a pretty big R&R list for my white '94 Aero.

What I'm aiming to do :
1. New timing chain, rails, and sprockets
2. New oil pump + front crank seal
3. New head gasket + head bolts
4. New water pump
5. Check condition of balance chain and guides and replace as needed.
6. New radiator (plastic near the upper radiator hose is cracked)


Fist off, is there any other big maintenance item that I should consider while I have everything apart?

Secondly, is there a source for the T-40 timing cover bolts? My '94 has these torx screws all over the place, and I've stripped two of them so far. I plan on welding another bolt on top of each, then remove as normal. Do later years still use these things? They seem to strip so easily, I'm wondering if it's just inherent in the bolt, my poor technique (I try to be as perpendicular as possible), or does the quality of your T-40 bit really make a big difference? How do you guys keep from stripping these things?

Also, how does one manage to remove the 13mm bolts which attach the intake manifold to the head? The upper and end ones are easy, but the bottom 3 are proving a challenge to hit and get turning. Any tricks?


Yeah, this is all being done in car. I have pictures, will post a write up once done.

posted by 71.36.88...

• Stripped T-40s - head gasket, timing chain on '94 Aero, BT, Mon, 27 Aug 2012 12:48:41 <-- Viewing This Message
  • As promised - in progress pictures, BT, Wed, 29 Aug 2012 16:24:25
    • Re: As promised - in progress pictures, Simon S, Wed, 29 Aug 2012 17:54:11
  • Ok, now I have the head off..., Name Left Blank, Wed, 29 Aug 2012 11:12:46
    • Re: Ok, now I have the head off..., Simon S, Wed, 29 Aug 2012 11:53:14
  • Re: Stripped T-40s - problem solved, BT, Wed, 29 Aug 2012 08:18:41
    • T-40 under waterpump, Gene N , Wed, 29 Aug 2012 10:16:54
      • Re: T-40 under waterpump, BT, Wed, 29 Aug 2012 11:03:14
        • Re: T-40 under waterpump, Wb, Mon, 19 Nov 2012 16:43:03
        • Re: Capcscrew under waterpump, BobS, Wed, 29 Aug 2012 12:02:33
  • Do need quality tools.., dref, Tue, 28 Aug 2012 08:40:39
  • Re: StuckT-40s socket head cap screws., BobS, Mon, 27 Aug 2012 19:50:54
  • Re: Stripped T-40s - head gasket, timing chain on '94 Aero, DickT , Mon, 27 Aug 2012 16:51:27
    • Re: Stripped T-40s: Older C900s had hex heads there., RayF, Mon, 27 Aug 2012 18:59:28
  • Re: Stripped T-40s - head gasket, timing chain on '94 Aero, Simon S, Mon, 27 Aug 2012 13:59:02
    • Re: Stripped T-40s - head gasket, timing chain on '94 Aero, BT, Mon, 27 Aug 2012 21:09:02

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