Piglet, I'm really going to depress you now because I know the hassle you had with those two bolts. You see, all you have to do to is remove the sump pan, you must remove the two torx studs completely and give it a few taps with a rubber mallet. If you don't remove the torx studs then you will not be able to break the sealant bond between the sump-pan and the crankcase and will be there for ages fighting with it. Once the pan is removed, all you have to do is remove the three M6 bolts that hold the metal oil pipe and the plastic pick-up to the underside of the crankcase. Once the three bolts have been removed you can the pull both the metal and plastic pick-up out from the sump. The metal return pipe is friction fit with an o-ring, up into the engine block. Once they are removed the timing case can be removed without having to remove either the torx bolt, or the hex bolt. All you have are two tails which can be left on and withdrawn with the timing case.
I did remove the torx bolt though, as I had been thinking about what was ahead of me before embarking on the case removal. I had it in my mind, from what you had told me, to use my minature Teng spanner and bits. It did allow me to remove the torx bolt easily. It is only about 2 1/2" long and has a ratchet on it, amazing for awkward places, well made as well.
Teng TM029 mini ratchet spanner and bits. Bloody handy little tool.
The metal pipe after being pulled out.
Back of belt after 50,000.
Water trickling out of mount bracket holes.
Coolant trickling out from behind timing case.
Oil pick-up and return pipes. Both can be removed after removing the three M6 bolts
and pulling them in a downward direction to basically, un-plug them.
Timing case out, at last! Very grotty around the water-pump area.
Piss-poor and flawed setup by Ford in my opinion.
Timing case, showing the two bolts underneath that the manuals don't mention.
The metal return pipe tail can be left on, as can the plastic pick-up tail (mine has been removed).
But they don't need removing to remove the timing case.