While searching for a way to increase the horsepower and torque out of my non-PI heads, I stumbled upon this "official article" about head leaks! It may already be in the tech. section of this site, but here is the address of the article for your review (and my nightmare!)

http://www.thedieselstop.com/faq/949...les/022207.pdf

 

So Ford hasn't eliminated the problem on the 2003s
Engine only been out 7 years
At least Chevy is fixing their knockers this year
Wonder what new problems the 5.43V is going to have
Ford sure as hell isn't filling me with confidence since 97
Probably still won't admit the spark plug problem
I wouldn't go near a used 5.4 or recommend one to anybody
My 93 is looking better every day

 

Very interesting read, and Unc I share your disgust if Ford hasn't fixed this particular problem (I thought they had). My only question is when you look at page 6 of the file, the engines it lists only go up through 2001.

Can one of you that's more familiar with Ford memos/bulletins tell me if I'm interpreting it correctly, but it looks to me like those are the engines affected by the problem, and the '02 and '03 model year engines aren't listed. Does this mean they're not likely to have this problem? If this IS the case, though, don't know why they'd list through the 2003 model year in the bulletin title...seems inconsistent with the engines listed.

What d'yall think?

Larry
Columbus

 

i work heavy line at a dealer. i've done numerous head gasket leak repairs. this article came out in late oct/early november.

i basically affects any and all 4.6 & 5.4 engines from 99-2003.

the updated gasket is an improvement over the old one. the embossed sealing surface is slightly larger in height and if i remember right sits closer to the Hopf cavity.

the problem can be due to what ford says is debris, warpage, brinneling, large scratches. however the design of the HOPF area is the main problem. the cavity is too large and the sealing surface at the rear of the head is too small. what results is a large cavity pressurized with very high oil pressure and a sealing surface that doesn't have enough clamping pressure to seal the oil pressure.

 

....AND JUST LIKE THAT!!!!!!!

........after everyone agonizing over this problem in thread after thread (including me, since I will be re-installing the Magnacharger bazooka boost pulley soon ) and just like that donovan provides the explanation!

THANKS DONOVAN!!!!!!!!!!

Also, since I may be changing heads soon, would it be a good ideal to install these "anti-leak" gaskets during the head swap




Hey Wittom! It looks like you "only" need a different gasket.

 

Donovan,
Thank you for your post. As an owner of a 99 Expy 5.4, that we just discovered has a seeping, right rear head gasket, and the plan is to install the new revised gasket on the 13th. I was hoping someone would post that knew more about the gasket than I was hearing. I am a little more comfortable with Fords, planned repair, than I was before reading your post. If the right side is leaking, what are the odds that the left side is too, or will be soon?

 

UncBob

So Ford hasn't eliminated the problem on the 2003s
Engine only been out 7 years
At least Chevy is fixing their knockers this year
Wonder what new problems the 5.43V is going to have
Ford sure as hell isn't filling me with confidence since 97
Probably still won't admit the spark plug problem
I wouldn't go near a used 5.4 or recommend one to anybody
My 93 is looking better every day


The 99's head gaskets leak was common but leaks are now rare. The piston's were redesigned in april 99 to help prevent piston slap - ford also replaced engines (chev did not as it was considered normal)

the 04 5.4 is using a longer skirt on there pistons to also help reduce any engine noise, different valve covers, etc

Different heads will be ofcourse be used so one would think the plug problem would be taken care of, but personally I'm not to concerned of this as it still is not as common as the head gasket leak

BTW my 99 had a head gasket leak - repaired with only a gasket, has slight piston slap on a cold day - ford offered to replace the engine but i decided to keep the original - no problems with the truck since.

The only thing I like about the chev truck is that there is more room to work on the engine

 

Thanks iron horse and donovan.
I printed this article for future use. I have a 97 Windsor built engine but I have purchased PI heads to install on a new Windsor short block I recently bought. My concern is there are a lot of heads available on Ebay where I bought mine. I think a significant number of these heads are from Dealers. Probably from engines that developed lower end problems but you never know. I will have my heads surfaced and get the new gaskets that are in the service article.
I'm still awaiting more information on the PI head swap. Eventually we will get it worked out.

 

I own a 99' F-250 Super Duty with a 5.4. I dicovered an oil leak on the back of the passenger side head at 68,000. that was may of 2001. I had the extened warranty to 75,000, so the problem was covered. I recently dicovered that it was leaking again. I now have 117,000. I took the truck back to the dealer and they offered to fix it but quoted me a price of $1100. I opted to try and get Ford to fix the problem because it had leaked once before. I contacted the quality dept. at Ford and they reviewed the case. They decided not to do anything about it because they had no record of there being a problem. I took the truck back to the dealer to have it fixed and they told me that Ford had issued a service bulletin stating the in order to fix the problem correctly, either the motor had to be pulled, or the cab had to be removed, thus resulting in a high cost of $1400. It was aslo brought to my attention that there had been some cases where the block was not flat, so I may need a new motor, $5900. If the block isn't flat, then it has been that was since it was new. Why should I have to pay for their mistake. I looked it to trading the truck in on a new one. The salesman told me that they would take at least $1100 off the dealer trade-in value. That is $4500. How couold someone justify spending $5900 on a new motor when the rest of the truck isn't even worth that. I'm still searching for some sort of resolution from Ford.

 

I'm having the same crap from my Ford dealer as well. Mine started leaking again at 42K miles. The service guy told me it would run around $1400 and they would only back that up with a 12 year/12K mile warranty.

 

I am bringing this back to the first page of engine threads for outdare's and wittom's review.

 

The way I look at it at this point is, if it breaks (or leaks in this case) it wasn't strong enough an should be repaired using better quality. If I do end up with a head gasket leak I will not have the option of having it repaired under warranty. I'm pretty much responsible for the entire drivetrain.

The E250 that I drive for work has a leaking head gasket. It's the 5.4. I'm not sure that it's worth it to fix it yet. I've read about too many people having the head gasket done then haveing it leak again in 10k.

I'll keep an eye on it.

 

Iron Horse,

Look at the second paragraph right hand side. It states they they are to remove engine to perform this test. So I guess the shop is doing it right. I am still nervous about anyone taken the engine out.

Bill

 

Chuck,

I was told the dealership I have taken my truck to for this same issue, He said that after the work is done it should be cover again by another 3 yr 36 K warranty.

 

Well, I'm in the 99 5.4 leaky head club. Actually, I've just had my second fix done. The truck has only 55,000 miles on it. The first leak was before the warranty expired, and Ford fixed it for no charge. Then about 3 weeks ago, I noticed oil all over my GD driveway. My first thought was Oh S**t, not again. I took it to the dealer hoping it was something else, but with the amount of oil and the fact that it was all over the place, I didn't get my hopes to high. Sure enough, the same d*mn right side head in the same spot in the back. I've got the extended warranty, so this time in cost me the $50 deductible. I also compared the work orders on the two repairs, and this time they pulled the motor, which they didn't do the first time. Work orders both times say head was checked for warpage, and found OK. Again, the repair is warrantied for 12 months/12,000 miles.

Which brings me to my question, and Donovan, if you could provide your opinion, I would really appriciate it. Should I trade this thing in and cut bait, or should I keep it? I only have about 6 months before this truck is paid for, and I'd like to keep it for several more years and get my Lightning this summer. But I don't want to shell out $1500 every 20,000 miles to fix the leak. My extended warranty runs out at 75,000 miles. Thanks for any input you guys may have.