How to Build a Ford 302 Small Block - Part 1: Removing the Intake, Heads and, Front Accessories

Today we start our ‪@SummitRacing‬ sponsored journey on rebuilding the very first engine I ever worked on. A Ford 302 small block out of a Bronco from 1981. We are going for a decently hot street build so we can wake up our old Bronco and churn out more than the 135 horsepower or so it made when new.
I am going to show you exactly how to rebuild this thing step by step and leaving no detail out! If you have any questions feel free to leave them below and I will get to them. Thank you so much for watching!
Engine Crane: www.summitracing.com/parts/su...
Engine Stand: www.summitracing.com/parts/su...
Bolts to Mount Engine on Stand: amzn.to/2RVsYG5
If you have a car question ask it completely free at www.2carpros.com/questions/new
*Disclaimer: Please use all safety precautions

[@danielmiller3967]

If you want to reuse old bolts, put them in a container of vinegar overnight. Wire brush them the next day and they will look brand new. Wash the vinegar off with baking soda and water then put some oil or wd40 on them to keep the rust from coming back

[@2carpros]

Great tip!

[@albertgaspar627]

The 302 officially came out in 1968, but in 1967 the 289 got the longer cylinder walls needed for the increased stroke. So if you want to stroke out a pre 1967 289 block (back in the day it was done with a machined Y block truck crank) you will find when the piston reaches BDC, it can come out of the bore just enough to rock around. So consider a modern roller cam block if you're going to go stroker--and if you nab an Explorer engine from the 1990's, you'll get the GT40P heads for free. The Mallory distributor is a good find (there are companies online who will rebuild or use it for parts), those who want an OEM high energy distributor like GM's HEI have to find an early 1980's unit that didn't require computers that came out in 1985-86. 302's come with two different weight flywheels over their lifetime so don't get it mixed up if you replace parts. I like to put old fasteners into a 50/50 brine of salt and vinegar, using the typical plastic containers your local deli sells you salads in. you can write on it exactly what is in there and they'll derust as you continue on with the engine--it'll probably work on that thermostat housing as well. when you pull a cylinder head, leave a couple of bolts in finger tight to hold it from dropping on your feet (dowel pins should do that, but if the engine's had a rebuild they may be missing). find what piston is at TDC, pull the spark plug, and run some compressed air into the chamber--even a bicycle tire pump could work. So long as the cylinder holds compression, the air pressure should pop it right loose for you

[@PotatoPapa101]

What an awesome informative video! I’m starting a 302 build and I wouldn’t be able to do it without your videos. Thank you!

[@2carpros]

Awesome! Let me know how it goes! Thanks for watching!

[@donaldfischer1428]

Great detailed video! I got ahold of a 302 out of a '73 mustang with the matching transmission. I tore it down like you did and stroked it to a 347. Used roller rockers and lifters. I put it in my '66 mustang. Now its faster than the speed of color!

[@2carpros]

NICE! That is so cool! Thanks for watching!

[@robertwest3093]

Those 347 builds are fun, even if you kept the stock heads, can reach 350 hp.

[@temper6162]

I had an 86 f150 with the 302, had a few issues, but ran great, plenty of power but my dad and I were gonna get rid of the EFI and put a carb on it, when I pulled the intake I saw bent pushrods, I swear it did not run like it had any internal damage, shocked everyone around lol, the ford small blocks, and even big blocks from back in the day we're amazingly resilient engines

[@2carpros]

Well now you have the excuse to rebuild it and put more power! Thanks for watching!

[@outsidethelines2162]

An other project! Lets go dude!!!

[@2carpros]

Heck yes! Here we go!

[@krisf5247]

Man what a great video! Great job. I love the detail you went into with the little things such as what to keep/ reuse etc. 👍🏻subscribed

[@2carpros]

Thanks for watching! 👍

[@VIP854]

I cant thank you enough for putting this video series together with this much detail! I picked up a 302 from a 99 Explorer that I going to rebuild with ACES EFI and shooting for 400 hp then shove it into a 90 Ranger! I plan to follow along as much as possible!

[@2carpros]

Nice! Sounds awesome!

[@11hotwings]

best to do it ! keep it up man. loved the 5.3 build !

[@2carpros]

Thanks! Will do!

[@josephcalabrese8665]

I have two 289 blocks ( 1965) A-code out of a Fairlane 500 both were running when pulled out. One has a crane cam, I brought it with new lifters, headers and a brand new holly 600cfm fired it up. Ran perfectly, just had to idle it down. Put it in a 73' ford f-150 with big dune diggers tires, ran real well in a 4000lbs + truck!!

[@mateovillanueva6063]

Thank you for this you’ve made me feel more confident in rebuilding my foxbody’s engine great fun learning experience!

[@thelamielousershow2896]

Bro thanks so much for making these videos!

[@2carpros]

My pleasure! Thanks for watching!

[@stenjohnson6149]

Probably the best overall video I've seen!

[@2carpros]

Thanks for watching!

[@davidbeutler7665]

Looking forward to next video

[@2carpros]

More to come! Thanks for watching!

[@eddievantailn2882]

Already fell in love with your channel.

[@sevans66]

Nice work, can't wait to see the next video

[@2carpros]

Thanks for watching Shawn! I just dropped it off at the machine shop 2 hours ago, so things are happening!

[@sevans66]

@@2carpros on a side note, got my 5.3 back from the machine shop. I can't believe how amazing it cleaned up. Like they gave me a new engine.

[@davidsimmons4491]

Thanks rebuilding a302 in my foxbody for fun this really helped

[@2carpros]

That's awesome! Please let me know how that goes!

[@seanash7134]

Love your videos bro!

[@2carpros]

Love your comment! Thanks for watching Sean!

[@toddmarks581]

I just wanna say I love you ❤️, this video series saved me $2500. I thought the machine shop was going to reassemble my sbf, but it was given to me in pieces 😨. I’m just starting to assemble and just trying to memorize all your videos on this sbf before I start

[@2carpros]

Great to hear!

[@gearjammer3200]

This video is perfect for me. I'm going to build my 302 for my 89 bronco.

[@2carpros]

NICE! That's basically this. Thanks for watching!

[@bigdaddy24811]

Can’t wait for the small block chevy series

[@2carpros]

Some day! In the mean time just watch the big block series and imagine it smaller. Thanks for watching!

[@madrabbit9007]

Couple of thoughts. First: shocked to see the FACTORY hose clamps! I really think they are a better design than the ones you can get at the parts house and would love to use them on all of my cars. Second: Had a 302 in an 84 Grand Marquis and had to change the water pump. Pretty sure Ford hung the water pump on a chain at the factory and proceeded to build the car around it. Three: Made the same sound you did when I spotted the bent push rods.

[@2carpros]

I agree those hose clamps work great. Yeah totally about the timing cover. Not the best design IMO. It was surprising to find bent rods! Thanks for watching!

[@bryanroupe8646]

I have a ton of the factory black hose clamps that come on the mustangs

[@glenncrockett4451]

I think that was the easiest I've ever saw a 5.0 Water Pump come off lol most I've dealt with were a Bitch lol

[@scottcrawford4148]

Nice logo!

[@jackyeomans7106]

Just finished watching the chevy big block series and really enjoyed it. Looking into restoring a mustang so this series is perfect! Thank you!!!

[@2carpros]

Nice! Thanks for watching Jack!

[@urielmoncayo7660]

Might buy a 1984 302 that's in a f150 so this series should help me a little or maybe a lot

[@2carpros]

Yeah it would be exactly the same. Thanks for watching!

[@justinmitchell4681]

New subscriber... I usely hate the small talk but the story was short and to the point it really made it worth it to me anyways short sweet and to the point thank you!!!

[@2carpros]

Awesome! Thanks for watching Justin!

[@johnelliott7375]

The alternator and air conditioner compressor, I love to rebuild them along with starters and distributors.

[@2carpros]

Nice!

[@bradcates8559]

I love these engine building series.

[@2carpros]

Well I love making them! Thanks for watching Brad!

[@isaacwolf8445]

Hey man I’m manual swapping my 302 and the bell housing I’ve bought has the starter motor port is on the drivers side, and the starter is on the opposite side,would it be possible swap the starter motor over? Hope that made some sense😂 Cheers

[@girlmeetsbronco]

I’ll be upgrading my 1971 Bronco’s 302 to a 347 Stroker. I’ve never worked on an engine before but I love how detailed this is. Would it be the same process?

[@shaywood2011]

i'm curious on how much wd-40 spray was used before doing this, especially after using your battery impact most of the time lol. I spent alot of time rebuilding my 302 front end with basic hand tools because it looked like that block. Bravo though, makes me glad to see that I still managed to do it the correct way.

[@2carpros]

None surprisingly. The thing was so greasy and gross it was pre lubed with ick haha Not to mention that battery impact kicks butt! Thanks for watching!

[@johnelliott7375]

Ford has been that way with the bolt lengths and diameters since the late 60's. Don't forget where they go or you're going to be playing in and out with the bolts on your water pump and timing cover.

[@2carpros]

I got new bolts any how but yeah.

[@markallen721]

For just under a $100 bucks at HDepot you can get larger casters to put on your eng. lift thereby allowing the eng. stand to roll under the eng. lift. saving your back man!

[@2carpros]

It has wheels on it. Thanks for watching!

[@DHunter52171]

You might try putting your stand frame and hoist stand with the leg V facing the same way

[@gagemancourt9674]

Could you possibly give us a website where you got all the new parts for, I’m currently working on a new 302 5.0 engine to go into my 89 Ford F-150 and it would be beneficial, and great video lots of help

[@2carpros]

Our sponsor! www.SummitRacing.com Thanks for watching!

[@michaelballash5309]

I have a 66 mustang with a 302 from around that time period want to purchase a 302 and build it up. My question would be should I look for an older 302 or would a newer one fit the bill

[@engihere5434]

I learned something while replacing my head gaskets, a 85 302 WILL run on only 4 cylinders and it wont sound to bad too lol, will die as soon as its in gear tho, replace fuel injectors and wires!!! Even if they dont look to old... THEY ARE

[@bayleyames07]

May I ask how much your roughly spent on new parts? Planning to do a rebuild and trying to get a good estimate

[@Carisus]

Can you slide the engine stand in backwards between the picker? Seems like it would be easier than scratching everything up and risking tipping something over.

[@2carpros]

If you have something that lets it spin freely from the hook. I don't have that luxury so I do this. Thanks for watching!

[@lionelwilliams9155]

When you get a Windsor 351w in maybe you could walk us through a series on rebuilding one

[@2carpros]

Maybe one day! This is super similar though. Thanks for watching!

[@ksman9087]

You forgot to mention draining the oil out of the oil pan before removing the flywheel bolts. Unlike Chrysler and GM V-8 engines from this era, the crankshaft flange on a Ford is drilled completely through. Removing the flywheel bolts before draining the oil will result in oil running out everywhere.

[@2carpros]

No it wont. The oil level is below the crankshaft. This engine had oil in it and you can see not a drop came out when I took the flexplate off. Thanks for watching!

[@ksman9087]

@@2carpros But if someone were to try to replace a flywheel with the engine still in the car, depending on the angle of the car on supports, oil will run out everywhere. I have seen it happen. I just thought that you might want to point this out because not everyone has an engine stand and an engine, even if removed from the car, could be setting at an angle where oil could run out and make a mess. I am not trying to be argumentative, just thought that pointing this out in a video might encourage viewers to drain the oil first and then no matter what angle the engine was setting when the flywheel bolts were removed there would be no mess. I DID enjoy the video. Keep up the good work.

[@halo_shepard7844]

Okay, I came across your videos, and you are the closest to the perfect professional video on 302 Windsor Engine. However, my question is I want to rebuild my 90 bronco and 89 Ford F150 5.0 which is also a 302. Will this work for me? Both of my engines are EFI. Please let me know asap, been starting at my phone for to long looking for answers and reading books with not much depth into it.

[@2carpros]

Yeah it should! I believe the only difference is the carbVSefi from stock. But we end up putting EFI on ours in the end with a Summit throttle body. Thanks so much for watching!

[@halo_shepard7844]

@2CarPros Thank you, this will be my first-time engine rebuild so I'm a little nervous but your videos have made me feel more confident. Thanks again

[@soylentgr3en]

Excellent video, ¿what DeWalt model do you use?

[@2carpros]

Thanks for watching! I use this for 3/8 www.amazon.com/DEWALT-DCF883B-20-Volt-Lithium-8-Inch/dp/B007NVSQEQ/ref=sr_1_7?crid=1XGFMKCU6ONH0&keywords=dewalt%2Belectric%2Bimpact&qid=1644949205&sprefix=dewalt%2Belectric%2Bimpact%2Caps%2C137&sr=8-7&th=1 And this for 1/2 www.amazon.com/DEWALT-Cordless-Impact-Wrench-DCF894B/dp/B078WDTV2F/ref=sr_1_4?crid=1XGFMKCU6ONH0&keywords=dewalt+electric+impact&qid=1644949205&sprefix=dewalt+electric+impact%2Caps%2C137&sr=8-4

[@jensfreeman6220]

Hey Ryan, I’m seeing a lot of talk that stroking a factory block could be problematic, what are your thoughts. I have a 302 out of an 89 f150. Please advise as I am wanting to build soon

[@miguelgarcia3178]

Hey man i have a 96 5.0 f150 ther harmonic balancer has 4 points and they dont make them but what can i use for the oe harmonic balancer

[@jackantoine5185]

Can you tell me the diameter of the oil pump drive on the distributor.. 1/2” or 5/16”. Thanks in advance Jack. PS. Well done video.

[@CyborgMedia]

Hi there! Thanks for these videos. I'm just wondering how much this project cost? So I can have a better idea of how much money I need to do something like this. Thanks!

[@2carpros]

Thanks so much for watching! This build was right around 7000 or so everything out the door.

[@jonhvilla8438]

Good work how come so little views? Is my first question.

[@2carpros]

Just hasn't gotten traction, our LS series did very well. Thanks for watching!

[@murkgaming7312]

what kind of dewault tool did you use?

[@isaachall7199]

How does this rebuild compare to a non roller 351w.?

[@harleyd9857]

No way in hell those exhaust manifold bolts came out that easy…

[@johnelliott7375]

Junked that valve train out, hopefully the bottom isn't junk . Balance the crank assembly will let you know for sure.

[@2carpros]

Considering it was hydro locked and had bent pushrods I wouldn't trust it in a new build. We ended up with a stroker kit so whole new bottom end that was balanced. Thanks for watching!

[@josemeza9207]

Will this work for a 1977 f150 with the 302

[@kaitlynrich5540]

Don’t be in a hurry to dispose of the parts There always a core for new or money wise you would have to use in a pinch

[@2carpros]

Yep! Hold on to your old parts. Thanks for watching!

[@Dylze]

I have a 2001 au falcon with a efi 302 Windsor, is anyone able to tell me the difference between the USA and AUS 302? Is one weaker than the other? And does any American manufactured performance part work with the AUS 302? Or are they 100% identical, sorry for all the questions, it’s just taken me a while to get the answers due to google and threads never explaining things properly

[@DannyNY]

Is there a way to tell I have bent push rods? My town car was sitting for a while it started it it may have been wet at the time.

[@2carpros]

Take the valve covers off and see if you can jiggle the rockers. If it wiggles a ton then you have one. Thanks for watching!

[@DannyNY]

@@2carpros I can’t do that that’s the only way? By sound? Will it ride rough?What about odb1 scanner?

[@2carpros]

@@DannyNY That's the easiest and fastest if you ask me. But if you have a bent pushrod you effectively have a dead cylinder that won't fire. It will run terrible if it even runs.

[@WayneKerrr]

Probably gonna be rebuilding a 302 myself soon. If you don't mind, or remember, would you be able to estimate about how much this build cost you?

[@2carpros]

Nice! Let me know how it goes! Hmmmm it's hard to put exact figure on it, especially with how nice but expensive the heads were. I'd go with something like 7 thousand. Thanks for watching!

[@WayneKerrr]

@@2carpros thanks for the knowledge!

[@jimmy6501]

I HAVE THIS ENGINE (1973 WINDSOR) IN MY BOAT AS A 188 HP MERCRUISER . I WANT TO REBUILD MINE AND BRING IT UP TO 300 HP, OBVIOUSLY WITH A MARINE CARB. SHOULD I BE DOING THINGS DIFFERENT THAN WHAT YOU ARE DOING IN YOUR VIDEO? THIS WILL BE MY FIRST ENGINE REBUILD. I AM VERY MECHANICALLY INCLINED.

[@2carpros]

I would do everything but the stroker kit then if you want 300hp or so. Thanks for watching!

[@DareBrad]

How similar is this motor to a 96 efi 5.0?

[@klashinkooff4749]

14:35 look at that beautiful in the back 😍🔥

[@2carpros]

Quite the looker isn't it? Thanks for watching!

[@joshuariehl6213]

Install a swivel and you can rotate the motor 360 degrees.

[@2carpros]

Yeah that would be good! Thanks for watching!

[@joshuariehl6213]

It works great. I did it on mine. I have the HF 2ton hoist and gear drive engine stand.

[@davidmoeller17]

do you have something showing the actual removal from car?

[@2carpros]

kzbin.info/www/bejne/sKqUdKKwgcyKi7M Thanks for watching!

[@davidmoeller17]

excellent. @@2carpros

[@danielpadgett2831]

Made this engine to I know to at least 1996 97.

[@johnelliott7375]

I would love to have that distributor for my motor build.😢

[@2carpros]

It wasn't sparking anyways. Now it's a Ford oil priming tool!

[@alfreddittberner5306]

Just a simple question...why not start with wash the engine?

[@2carpros]

Because I don't like dealing with wet parts but it's just a preference. Thanks for watching!

[@markwoten6679]

That power steering pulley is hard to find so lock it up. 😮.

[@2carpros]

Oh it's locked away! Thanks for watching!

[@DannyNY]

My 1989 Town car has a 302... but only 150hp

[@DannyNY]

Is my engine like this?

[@2carpros]

Yeah I believe they are same. Probably a different oil pan and intake but the rest are super similar. Thanks for watching!

[@DannyNY]

@@2carpros but with so much less horse power? Will it be more simple to work on? What are the key components that are different?

[@swk1610]

Next time spin the engine stand around or hook the engine the opposite way

[@2carpros]

Then the hook will want to spin when you lift it in the air.

[@AraceaeFanatics]

The Ford small block ran from 1962 - 2001. The 302(4.9L/5.0L) ran from 1967 - 2001, finishing the family's run in the Ford Explorer.

[@stevenbaker5099]

And the Mercury Mountaineer ('95-'01).

[@GearheadRob319]

Ford built the 302 up to 2001.

[@2carpros]

Yep. Thanks for watching!

[@TheMotorEddy]

I see you're using regular Cro-moly sockets on your impact gun. Don't do this - they're brittle, compared with a proper impact socket, and can shatter.

[@2carpros]

Technically correct, but I've been doing it for ever and it seems fine as long as you have high quality sockets. Thanks for watching!

[@robotseattrees9386]

Yesterday I went to a race parts and repair shop I practically begged the guy to take $5k from me. I'm in desperate need of a 302 for my truck and no one will help me. Also I'm not fond of atk engines I had bad luck in the past with that company

[@2carpros]

Maybe time to build your own? Thanks for watching!

[@johnelliott7375]

Shame, a young man or woman out there pressed for money could use those parts for a budget build and might not have the money that you have to get 400-500 dollar roller rockers.

[@2carpros]

If they were there I'd happily give them to them.

[@user-ey3mb8jz9l]

Boring, to much explaining