I hate to bring this up since it looks like it usually spawns an emotional debate but...
Im just looking to get the skinny on the pre-98 engine gasket issue.
Basically, are the 97s the ONLY ones now that have gasket problems(front cover, head, and intake)?
Is that the ONLY difference between the 97 and later engines(will changing all the gaskets out to the later spec gaskets make a 97 just as good as a 99?)?
Are headgasket failures common as well, or is it usually just intake or front cover gaskets that are misdiagnosed as headgasket failures?
Are there any other parts that need to be changed when upgrading to the newer gaskets? Like, is there a new front cover needed to mate to the new gasket or something?
I take it when the front cover gasket goes bad you end up mixing water and oil, and when the intake gaskets go bad you end up burning water and possibly hydrolocking the engine? Whats this do to the cats? I know the easiest way to get the brick out of a cat is to soak it in water for a few hours and the brick will melt and run right out with a hose.

Thanks!

 

It's not very complicated.

This is a list of engines that require the revised gaskets:



If the engine (Not the vehicle) were built after 1/15/98, it has all of the updated, durable gaskets.

• If you have a 1997 model year F-150 with a 4.2L engine, you absolutely have an engine built with obsolete lower intake gaskets. These gaskets have failed on many of these engines, at a much higher rate than average.
  
• If your engine was built prior to 5/01/97, it was also assembled with a faulty engine front cover gasket.
  
• If your truck was built between 11/1/95 & 12/31/96, your truck was also included in "Owner Notification Program 99B29" to replace this faulty engine front cover gasket.
  
• If your engine was built between 01/01/97 & 05/01/97, it was assembled with the same faulty front cover gasket but, your truck was not included in the recall.
  

I haven't found anything that indicates these head gaskets are faulty by design or any common installation errors. I believe the head gasket failures people have commented on are either the result of an overheated engine or a false diagnosis. Part of the problem is that when an intake gasket fails, the result can indicate a head gasket failure. I pretty sure that a few mechanics have misdiagnosed a failed intake gasket as a failed headgasket and the owner was none the wiser; The intake gaskets have to be removed and replaced in order to replace a head gasket, so who would know???

The gaskets themselves as well as the installation procedure ( including the torque value of the bolts) is the problem. Changing the gaskets and using the updated torque values is all that is necessary.

When the front cover gasket fails, coolant can leak into the engine oil.

When the lower intake gasket fails, coolant can leak into the engine oil and/or the intake manifold itself, where it enters the combustion chamber.

The lower intake failures seem to offer a very sudden death for many of these engines. You shut the engine down and when you restart it, the cylinder is full of coolant and you bend or break a rod.

The lower intake leaking into the oil is a bit slower. This is what my oil looked like a few days after my lower intake gasket blew. Driving around for a few days with a couple quarts of coolant in the oil will create the need for an engine overhaul.

On a positive note: coolant in the combustion chamber does remove carbon build-up

 

AJ,

I have a 97 4.2L built 4/15/96. I have been in for the 99B29 front cover gasket replacement. Ford notified me of the TSB/recall but charged the $431 against the ESP warranty that was in effect at the time, so I don't know what's up with that. Anyway, I never was called in for the lower intake gaskets, but I'm having a starting problem lately and was wondering if maybe the gasket(s) are the culprit.

Over the past week or two I have often had to crank the truck 5, 6 or even more times before it starts. Sometimes it will start on the first try, but mostly not. I have no "check engine" light or other unusual sounds, leaks, smoke, etc...

However, today, when I was fiddling with it, I noticed that after I turned it off (it had idled for about 10 mins) I could hear a hissing type noise coming from the passener side upper engine area. It didn't exactly sound like air, but it was similar to hearing the a/c system equalize after it has been running (a/c, defrost was off today).

Could an intake gasket leak cause these symptoms?

Thanks.

 

Bob,I am now telling everyone to get the lower intake gaskets replaced on ANY and EVERY 97 4.2! I,under heavy advice from AJ and TallTom,had mine replaced in Oct.02.The Ford tech said mine was a time bomb ready to explode if I had not replaced them!So,anyone out there with a 97 4.2V6,GO GET THE LOWER INTAKE GASKETS REPLACED!!!!Your time is coming when they will fail if you dont!!

 

Oval,

After reading everything I could find over the 48 hrs., I agree that I need to get my intake gaskets changed asap whether it solves my current problem or not. I just really want to be sure that I'm not missing something else, as well.

What can I expect to pay to the dealer to change the intake gaskets - any idea?

 

My total bill was 499.65.....that included; labor,gaskets,(2) gallons of coolant,oil change and I had them rotate and balance my tires.Minus the R&B,you are looking at about 475.00.Oh,and they used some BG cleaner on my lower intake.I only trusted Ford to do this work.Seems ironic,huh?

 

Okay,
My truck has 135K on it. I know it has either a blown headgasket, intake gasket leakage or both. It puffs when it starts, has a rough chug at first like Bob, etc. It DOES NOT appear to have water mixed with the oil(do not have cream on the dipstick).
The bad thing is I bought the truck this way, so I do not know how long the previous owner drove it in this condition. I bought it from a lot, and the lot said the owner brought it in because of the problem. Atleast the owner knew something was wrong, and suspected it to be a headgasket so hopefully he didnt drive it too long that way.
My original intent was to scoop up a crate motor for it and stick it in, but after seeing prices on them I may hold out a while. I was hoping to find a new longblock for about 1200, but all that is available from Ford is remans for 1900. At that price I will put another 75K on it first.
Anyhow, are the heads on these prone to cracking, or are they pretty stout? I know the 3.0s are very tempermental, but the 2.3s for instance are tough as nails. Where does the 4.2 lie?
I checked compression yesterday. Even though the engine cranked over a little slow(battery getting weak) putting the gas to the floor while cranking showed 180psi on the lowest cylinders with one up around 210. Those numbers seem pretty good, but think its possible the headgasket is still blown? I am going to change them anyhow I think while I have it torn down to be safe, but....
My biggest fear is a bent rod, but am unsure how to check for this. I can come up with ways I can guess how to do it, but wonder how real mechanics do it in the real world. All I can think of is either a depth mic check, or feeler gauges under a straight edge. What kind of tolerance is acceptable?
Think the rod(s) could be bent even if it runs smooth once it starts up?
Also, is some valve train noise normal from these engines? Sounds like a light ticking coming from the valve cover area.

 

I am replacing my 4.2 97 engine, with a rebuilt one. Where can i get the new torque values for the intakes? I am going to make sure that the rebuilders have the new gaskets.


thanks

 

At first I was going to say I did not know, and I was going to wait for someone else to answer. Then I looked at the TSB 99-20-7 and it states:
NOTE: FOR 4.2 UPPER INTAKE MANIFOLD(ONLY): DO NOT TIGHTEN THE BOLTS TO THE TORQUE VALUE LISTED IN THE SERVICE MANUAL. THE BOLT SEQUENCE HAS REMAINEDTHE SAME BUT THE TORQUE VALUE HAS CHANGED TO 8Nm(71lb-in) ANDTHEN TIGHTEN ALL BOLTS AND ADDITIONAL 90 DEGREES

It has another note that states:

NOTE: DUE TO SLIGHTLY THICKER SIDE GASKET BEAD MATERIAL, THE CENTER BOLTS(#3 AND #4 IN FIGURE 1) IN THE LOWER INTAKE MANIFOLD MUST FIRST BE INSTALLED(HAND TIGHTENED) AND FASTENED. DRAWING DOWN THESE BOLTS FIRST WILL FACILITATE INSTALLATION OF THE OTHER BOLTS.

I will try to explain the location of these two bolts..
For the first one, if you are infront of the engine looking down look at the passenger side intake ports. There should be a bolt hole just behind the center set of ports. That is #3.
#4 is in a similar location on the drivers side. It is located just in front of the center set of ports for the driver side.
I strongly suggest you pick up a manual either from Faxon, or look on EBay for people sellingthe factory manuals on CD. The torque specs on this stuff is VERY low.

 

I im looking into buying a 97 f150 4x4 4.2 v6 w/ 81k miles. After hearing about the whole gasket situation, I'm not so sure I wanna. Do they usually go around a certain amount of mileage, or just randomly? The truck is a one owner, but I'm buying it from a dealer. Is there a way to find out if they have been replaced? Can you tell by looking at certain parts of the motor to see if it has been apart? Please help?

 

I would get a cost on having the gaskets replaced and have him take that off of the price. Or the dealer can do it. Either way, get them replaced.