Progress Thread Diagnosis front end clunk (and more)

Whats the pros and cons if any between 4 flute or 3 flute tap?

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To clean out threads a thread chaser is the tool for the job. Taps are really aggressive designed to cut new threads. Chasers are meant to restore existing threads.

As for the 3 vs 4 flute taps, no idea.

At least you used a band aid. I usually use electrical tape lol.
 
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The back of the Tuff Stuff water pump is different so I pressed and imprint and penciled in a line to trim the stock replacement gasket of the excess material that should not be left in there.

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I’m thinking I’m going to remove the old hub seal and install the timing cover onto the engine before I install the new hub seal. This pcv fitting will make a perfect installer. It fits over the crank snout and its outside diameter is just about perfect for driving the seal in.

I figure without the seal in place when putting the cover on, I’ll have more range of movement to go in a little high then push the lower part of the cover down into the lower pan radius seal. Also prevent damaging the new hub seal while gaining extra range of motion for installation.

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Public Service Announcement

For those of you like me, who also stab their thumbs with razor blades while scraping gaskets, here are the specific Bandaids you need to have on hand. They are very good

Tough Strips

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If a person expects to have even minimal rtv on both the water jacket surface and the crankcase surface it seems almost impossible that rtv will stay out of that weep slot.
I believe factory installed the gaskets dry. I’ve tried it (others here have as well( and got a leak shortly after. Have used RTV ever since.
 
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I test fit the cover install process with the old hub seal still in place and had no trouble getting it properly installed. I can install the new hub seal in the cover before I install the cover to block and have plenty of free movement to get easily together correctly.

I had the original pan radius seal on the cover during this test fit. Its thicker and it also fits the existing rubber pan gasket perfectly so I’ll reuse it in the final install.

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I found these pictures on FB and it looks like normal stock tube. When I rebuilt this engine, not too many miles ago I used a standard volume stock pump. I probably went through this question back then too, but just don’t remember.