How to remove the piston and connecting rod assemblies on Mercury Cougar?

Prior to removing the piston and connecting rod assemblies, the cylinder heads, oil pan, and oil pickup must be taken off. First, completely remove the ridge at the top of each cylinder using a ridge reaming tool, following the manufacturer's instructions, as failure to do so may result in piston breakage. After the ridges are removed, turn the engine upside down so the crankshaft is facing up. Before removing the connecting rods, check the endplay with feeler gauges, ensuring the play is eliminated; if the endplay exceeds the service limit, new connecting rods may be necessary. Check the connecting rods and caps for identification marks, and if they are not marked, use a small center punch to create indentations. Loosen each connecting rod cap nut half a turn until they can be removed by hand, then take off the number one connecting rod cap and bearing insert, ensuring not to drop the bearing insert. To protect the crankshaft journal and cylinder wall, slip a short length of plastic or rubber hose over each connecting rod cap bolt before removing the piston. Push the connecting rod and piston assembly out through the top of the engine, using a wooden hammer handle to assist, and if resistance is felt, verify that all ridge material has been removed. Repeat this process for the remaining cylinders, and after removal, reassemble the connecting rod caps and bearing inserts in their respective rods, installing the cap nuts finger tight to prevent accidental damage to the bearing surfaces.

Genuine Mercury Cougar Piston

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Mercury Cougar Piston
Part Number: E9TZ-6108-DB
$19.28 MSRP: $26.34
You Save: $7.06 (27%)
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Product Specifications
- Warranty: This genuine part is guaranteed by Ford's factory warranty.
Fits the following Vehicles:
- 1985-1989 Mercury Cougar | 4 Cyl 2.3L, 6 Cyl 3.8L, 8 Cyl 5.0L | 3AT C5, 4AT AOD, 5MT
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Mercury Cougar Piston
Part Number: F3AZ-6108-CB
$21.81 MSRP: $29.81
You Save: $8.00 (27%)
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Product Specifications
- Manufacturer Note: .50mm/.020" oversize
- Warranty: This genuine part is guaranteed by Ford's factory warranty.
Fits the following Vehicles:
- 1994 Mercury Cougar | 8 Cyl 4.6L | 4AT, 4AT AODE
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Mercury Cougar Piston And Pin Assembly
Part Number: F5AZ-6108-BA
$32.79 MSRP: $44.81
You Save: $12.02 (27%)
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Product Specifications
- Other Name: Piston And Pin Assy
- Replaced by: 8L2Z-6108-G
- Warranty: This genuine part is guaranteed by Ford's factory warranty.
Fits the following Vehicles:
- 1995-1997 Mercury Cougar | 8 Cyl 4.6L | 4AT, 4AT 4R70W, 4AT AODE
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Mercury Cougar Piston & Pin Assembly
Part Number: F2ZZ6108DB
$45.13 MSRP: $62.70
You Save: $17.57 (29%)
Ships in 1-2 Business Days
ADD TO CART
Product Specifications
- Other Name: Piston And Pin Assy
- Warranty: This genuine part is guaranteed by Ford's factory warranty.
Fits the following Vehicles:
- 1991-1992 Mercury Cougar | 8 Cyl 5.0L | 4AT AOD
- 1986-1989 Mercury Cougar | 4 Cyl 2.3L, 6 Cyl 3.8L, 8 Cyl 5.0L | 3AT C5, 4AT AOD, 5MT
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Mercury Cougar Piston And Connecting Rod Assembly
Part Number: 1S7Z-6100-DA
Product Specifications
- Other Name: Piston And Connecting Rod Assy
- Manufacturer Note: Complete assembly, piston,pin,rings,rod, without highout high output SVT
- Warranty: This genuine part is guaranteed by Ford's factory warranty.
Fits the following Vehicles:
- 2001 Mercury Cougar | 6 Cyl 2.5L | 4AT CD4E, 5MT
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Mercury Cougar Piston And Connecting Rod Assy
Part Number: 1U2Z-6100-AA
Product Specifications
- Warranty: This genuine part is guaranteed by Ford's factory warranty.
Fits the following Vehicles:
- 2001-2002 Mercury Cougar | 6 Cyl 2.5L | 4AT CD4E, 5MT
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Mercury Cougar Piston
Part Number: E6TZ-6108-FB
Product Specifications
- Warranty: This genuine part is guaranteed by Ford's factory warranty.
Fits the following Vehicles:
- 1980-1985 Mercury Cougar | 4 Cyl 2.3L, 6 Cyl 3.3L, 6 Cyl 3.8L, 8 Cyl 4.2L, 8 Cyl 5.0L | 3AT C3, 3AT C4, 3AT C5, 4AT AOD, 4MT, 5MT
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Mercury Cougar Piston & Pin Assembly
Part Number: E8DZ6108FB
Product Specifications
- Other Name: Piston And Pin Assy
- Warranty: This genuine part is guaranteed by Ford's factory warranty.
Fits the following Vehicles:
- 1988-1995 Mercury Cougar | 6 Cyl 3.8L, 8 Cyl 5.0L | 4AT, 4AT AOD, 4AT AODE, 5MT
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Mercury Cougar Piston & Pin Set
Part Number: E9DZ6108HB
Product Specifications
- Other Name: Piston
- Warranty: This genuine part is guaranteed by Ford's factory warranty.
Fits the following Vehicles:
- 1988-1993 Mercury Cougar | 6 Cyl 3.8L, 8 Cyl 5.0L | 4AT AOD, 5MT
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Mercury Cougar PISTON AND PIN ASY
Part Number: E9TZ6108AB
Product Specifications
- Other Name: Piston
- Warranty: This genuine part is guaranteed by Ford's factory warranty.
Fits the following Vehicles:
- 1985-1989 Mercury Cougar | 4 Cyl 2.3L, 6 Cyl 3.8L, 8 Cyl 5.0L | 3AT C5, 4AT AOD, 5MT
View related parts
Mercury Cougar Piston & Pin Assembly
Part Number: E9TZ6108BB
Product Specifications
- Other Name: Piston And Pin Assy
- Warranty: This genuine part is guaranteed by Ford's factory warranty.
Fits the following Vehicles:
- 1985-1989 Mercury Cougar | 4 Cyl 2.3L, 6 Cyl 3.8L, 8 Cyl 5.0L | 3AT C5, 4AT AOD, 5MT
View related parts
Mercury Cougar Piston & Pin Assembly
Part Number: F2ZZ6108EB
Product Specifications
- Other Name: Piston And Pin Assy
- Warranty: This genuine part is guaranteed by Ford's factory warranty.
Fits the following Vehicles:
- 1991-1992 Mercury Cougar | 8 Cyl 5.0L | 4AT AOD
- 1986-1989 Mercury Cougar | 4 Cyl 2.3L, 6 Cyl 3.8L, 8 Cyl 5.0L | 3AT C5, 4AT AOD, 5MT
View related parts
Mercury Cougar Piston & Pin Assembly
Part Number: F2ZZ6108FB
Product Specifications
- Other Name: Piston And Pin Assy
- Warranty: This genuine part is guaranteed by Ford's factory warranty.
Fits the following Vehicles:
- 1991-1992 Mercury Cougar | 8 Cyl 5.0L | 4AT AOD
- 1986-1989 Mercury Cougar | 4 Cyl 2.3L, 6 Cyl 3.8L, 8 Cyl 5.0L | 3AT C5, 4AT AOD, 5MT
View related parts
Mercury Cougar Piston And Pin Assembly
Part Number: F5AZ-6108-A
Product Specifications
- Other Name: PISTON AND PIN ASY
- Warranty: This genuine part is guaranteed by Ford's factory warranty.
Fits the following Vehicles:
- 1994-1997 Mercury Cougar | 8 Cyl 4.6L | 4AT, 4AT 4R70W, 4AT AODE
View related parts
Mercury Cougar Piston & Pin Assembly
Part Number: F6SZ6108BA
Product Specifications
- Other Name: Piston And Pin Assy; Piston
- Warranty: This genuine part is guaranteed by Ford's factory warranty.
Fits the following Vehicles:
- 1989 Mercury Cougar | 6 Cyl 3.8L | 4AT AOD, 5MT
View related parts
Mercury Cougar Piston And Pin Assembly
Part Number: F6ZZ-6108-AA
Product Specifications
- Other Name: Piston And Pin Assy
- Warranty: This genuine part is guaranteed by Ford's factory warranty.
Fits the following Vehicles:
- 1996-1997 Mercury Cougar | 6 Cyl 3.8L | 4AT 4R70W
View related parts
Mercury Cougar Piston And Pin Assembly
Part Number: F6ZZ-6108-BA
Product Specifications
- Other Name: Piston And Pin Assy
- Warranty: This genuine part is guaranteed by Ford's factory warranty.
Fits the following Vehicles:
- 1996-1997 Mercury Cougar | 6 Cyl 3.8L | 4AT 4R70W
View related parts
Mercury Cougar Piston And Pin Assembly
Part Number: F6ZZ-6108-CA
Product Specifications
- Other Name: Piston And Pin Assy
- Warranty: This genuine part is guaranteed by Ford's factory warranty.
Fits the following Vehicles:
- 1996-1997 Mercury Cougar | 6 Cyl 3.8L | 4AT 4R70W
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Mercury Cougar Piston Rings & Bearings
Part Number: F8CZ6108AA
Product Specifications
- Other Name: Piston And Pin Assy; Piston
- Warranty: This genuine part is guaranteed by Ford's factory warranty.
Fits the following Vehicles:
- 1999 Mercury Cougar | 4 Cyl 2.0L | 4AT CD4E, 5MT
View related parts
Mercury Cougar Piston And Connecting Rod Assembly
Part Number: XS2Z-6100-BA
Product Specifications
- Other Name: Piston And Connecting Rod Assy
- Warranty: This genuine part is guaranteed by Ford's factory warranty.
Fits the following Vehicles:
- 1999-2001 Mercury Cougar | 6 Cyl 2.5L | 4AT CD4E, 5MT

Mercury Cougar Piston

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Mercury Cougar Piston Parts Questions & Experts Answers

Piston
E9TZ-6108-DB
Q: How to remove the piston and connecting rod assemblies on Mercury Cougar?
A: Prior to removing the piston and connecting rod assemblies, the cylinder heads, oil pan, and oil pickup must be taken off. First, completely remove the ridge at the top of each cylinder using a ridge reaming tool, following the manufacturer's instructions, as failure to do so may result in piston breakage. After the ridges are removed, turn the engine upside down so the Crankshaft is facing up. Before removing the connecting rods, check the endplay with feeler gauges, ensuring the play is eliminated; if the endplay exceeds the service limit, new connecting rods may be necessary. Check the connecting rods and caps for identification marks, and if they are not marked, use a small center punch to create indentations. Loosen each connecting rod cap nut half a turn until they can be removed by hand, then take off the number one connecting rod cap and bearing insert, ensuring not to drop the bearing insert. To protect the crankshaft journal and cylinder wall, slip a short length of plastic or rubber hose over each connecting rod cap bolt before removing the piston. Push the connecting rod and piston assembly out through the top of the engine, using a wooden hammer handle to assist, and if resistance is felt, verify that all ridge material has been removed. Repeat this process for the remaining cylinders, and after removal, reassemble the connecting rod caps and bearing inserts in their respective rods, installing the cap nuts finger tight to prevent accidental damage to the bearing surfaces.