Serious Explorations Ford Explorer and Ranger Message Board
#1 Resource for Ford Explorer and Ranger Owners - By Enthusiasts, for Enthusiasts.


Ford Explorer Generation Guide

Members Rides 2016 Ford Explorer Forums Elite Membership Chat Room My Posts Reviews Explorer Gallery
Go Back   Ford Explorer and Ranger Forums "Serious Explorations" > Ford Explorer Ranger Repair - Troubleshooting - Modifications & Detailing Forums > 2002 - 2005 Explorer Mountaineer 3rd Generation > Stock 2002 - 2005 Explorers

Notices

Stock 2002 - 2005 Explorers Questions related to non-modified 2002 - 2005 Explorers and Mountaineers. Problem solving, maintenance, TSB, service bulletins, owner reviews, specifications. Sport Trac and Sport use the 1995-2001 forum.

2002 4.0L V6 valve cover gasket replacement and TIPS!

Reply
 
Thread Tools
Old 03-19-2012, 09:27 PM   #1
thammel
Baltimore, MD
2002 XLS
 
Join Date: Sep 2004
Posts: 93

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 0 Post(s)
(Original Poster)
2002 4.0L V6 valve cover gasket replacement and TIPS!

I got sick and tired of the aroma of burnt oil on the exhaust manifolds....every time at a stop light the fumes would be overwhelming! So I finally bit the bullet and did this job. It's a pain! You need to remove the intake manifold to get access to the valve covers. It's a good idea to replace the manifold seals while at it. Basic tools can get the job done with a couple of exceptions. You'll need 1/4" drive small torx sockets (ok, pretty basic) to get the intake manifold screws out. You'll also need an inspection mirror to see the driver's side rear screw. The worst part was the egr tube. Here's where you'll need a 27 mm open end wrench and probably a 27 mm crowfoot wrench, 1/2" drive. I was able to get the tube nut loose at the top end (egr valve) but had real problems at the header. There appears to be a fitting screwed into the header and then the tube with nut screws into that. I could NOT break the two loose but could only turn the tube with nut attached to the fitting. The problem with this is that it didn't allow the tube to be removed, so I forced and bent the tube enough to get the valve (right side) cover off. This made it really difficult to get the tube back in, come assembly time, but I managed. I think you'll need a 25 mm open end wrench to hold the fitting while you loosen the tube nut with the 27 mm crowfoot wrench.

The good news is that the job is done and there are no more oil leaks. And it started up immediately.

I was lazy and didn't remove the negative battery cable. I also did not relieve fuel system pressure. Got just a little leak on disassembly - no biggie. So if you have any specific questions on this job, I think I can answer them now.

Tom
thammel is offline   Reply With Quote
( Join the Elite Explorers )

Join the Elite Explorers for only $20 a year. Explorer Forum has probably saved you that much already, and will continue to save you money as you learn how to diagnose and fix problems yourself, and learn which modifications really work without having to experiment on your own. Elite Explorer members can change the forum "styles" to eliminate most ads, including blue underlined links, and no ads on photos. Other benefits include the ability to store 1000 Private Messages, upload photo attachments directly to your posts and to our Photo Gallery and more. Join the Elite Explorers today.


Old 03-22-2012, 01:20 PM   #2
mikbor1
Sugarloaf, New York
03 XLT
 
Join Date: Feb 2007
Posts: 27

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 0 Post(s)
I recently did mine also--To break free the large nut for the EGR on the mainfold I actually removed the passenger side inner fenderwell and stuck a large pipe wrench thru there onto the nut--I only got a 1/4 turn at a time, but it worked!!
mikbor1 is offline   Reply With Quote
Old 04-16-2012, 08:11 PM   #3
mdboulier
atlanta, ga
'02 XLT
 
Join Date: May 2010
Posts: 7

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 0 Post(s)
Thanks for the write up. I have to make the same repair to my 02 explorer. Its been fun going around town smelling like burnt oil but enough's enough.

Last edited by mdboulier; 04-16-2012 at 08:19 PM. Reason: hahaha wrong instructions
mdboulier is offline   Reply With Quote
Old 01-08-2013, 09:59 PM   #4
vrtentis
Jacksonville, fl
2001 ford explorer sport
 
Join Date: Nov 2011
Posts: 9

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 0 Post(s)
the bolt on the driverside closest to the firewall has oil pooling up and over flowing onto my headers! any idea why it would do this? just replaced gasket and bolt grommets (felpro) do I need silicone? do the longer guide bolts go on first then the cover? im out of ideas? could my valve cover be warped?
vrtentis is offline   Reply With Quote
Old 01-09-2013, 07:25 AM   #5
mikbor1
Sugarloaf, New York
03 XLT
 
Join Date: Feb 2007
Posts: 27

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 0 Post(s)
I believe they are plastic so maybe it cracked? Also the pvc valve is there, maybe the oil is leaking from there
mikbor1 is offline   Reply With Quote
Old 01-13-2013, 06:59 PM   #6
vrtentis
Jacksonville, fl
2001 ford explorer sport
 
Join Date: Nov 2011
Posts: 9

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 0 Post(s)
black hole

You were more than right about a crack, the was a hole in the back of the cover. Not sure what caused it maybe heat stress or just got old. Either way ordering a new set thanks for your reply.
vrtentis is offline   Reply With Quote
Old 01-14-2013, 04:41 AM   #7
vrtentis
Jacksonville, fl
2001 ford explorer sport
 
Join Date: Nov 2011
Posts: 9

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 0 Post(s)
Anyone have a good website to buy a good replacement set of valve covers? Or a part number? Ford wants $108 per cover and I figured maybe for that price i might find a better quality material from a after market company.
vrtentis is offline   Reply With Quote
Old 01-24-2013, 05:40 PM   #8
mrau92me
Decatur, AL
'02 Mountaineer
 
Join Date: Jan 2010
Posts: 96

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 3 Post(s)
Quote:
Originally Posted by vrtentis View Post
Anyone have a good website to buy a good replacement set of valve covers? Or a part number? Ford wants $108 per cover and I figured maybe for that price i might find a better quality material from a after market company.
I'd be tempted to try drilling a little bit larger hole in that spot and then install some sort of plug made to fit that size hole. If you're set on replacing that cover, try some of the on-line Ford dealerships that typically sell their parts for cheaper. They've been mentioned here in this forum several times, something like silverstate ford, Tasca Ford, genuinefordparts (something like that), etc.

A hole sounds awfully strange...like someone else mentioned, are you sure you put your pcv valve back in? BTW, if you replaced the pcv valve with a metal Standard brand valve, there's a good chance it's not the right part and will pop out of the valve cover. My local parts store sold me one insisting it would fit, and I had to take it back with my original one. They then agreed it wouldn't work.
mrau92me is offline   Reply With Quote
Old 04-06-2013, 02:17 PM   #9
Jasone352
Ocala, FL
'02 explorer xlt
 
Join Date: Mar 2012
Posts: 23

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 0 Post(s)
Unhappy

Okay so i am in the process of replacing my valve covers today, i am about 3 hours in and spent the majority of that trying to get that god-forsaken right rear intake manifold screw out. After much effort I have all 8 removed, as well as the throttle body, spark plug wires, and numerous other hoses and tubes. However, I am going to make a trip down to the tool shop and pick up those recommended wrenches in order to get the EGR tube off. Hopefully then I can start working on replacing the actual valve cover gaskets.

Now I have a few questions:

1. When replacing the intake gaskets/ valve cover gaskets, is there some kind of sealant/lubricant I must apply before reassembling? I believe I have seen mention of something of the sort on other threads but I am not positive.

2. Neither the replacement gaskets i purchased for the intake or the valve covers came with any kind of grommets that I have seen mentioned. What are these and do I have to replace these as well? I dont believe my Hayne's manual makes any mention of them.

3. When cleaning the gasket surfaces on the intake and the valve cover, brake fluid will suffice? I know to be careful as to not get any gunk inside of the engine, however I want to be sure I am properly cleaning the surface before reassembling.

Sorry for the bombardment of questions, hopefully someone replies soon since i will be riding my bike to the store here shortly

Thanks for the help everybody!
Jasone352 is offline   Reply With Quote
Old 12-29-2013, 08:19 PM   #10
Hitchhikingmike
Dallas, Texas
'02 XLS
 
Join Date: Jan 2008
Posts: 1,538

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 5 Post(s)
My 2002 is burning oil on the headers on both sides now. To make the matter worse I already replaced the valve cover gaskets 3 or 4 years ago. Even then it wasn't as bad as it is now. I just degreased the engine to watch it seep from the valve cover to make sure.

I hope my cover isn't warped or cracked. Coincidently both sides are leaking oil onto the manifolds.

Fml. The first time I did the job I took the egr pipe off of the manifold and it was tough. Hopefully it won't be any harder this time since I have previously broken it loose.

:/ GHAD!!!




__________________
-Mike
Hitchhikingmike is offline   Reply With Quote
Old 12-29-2013, 08:27 PM   #11
Hitchhikingmike
Dallas, Texas
'02 XLS
 
Join Date: Jan 2008
Posts: 1,538

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 5 Post(s)
I think I'll apply a bead of silicon on the outside perimeter of the valve cover gasket this time to double seal it. Think this would be a good idea?




__________________
-Mike
Hitchhikingmike is offline   Reply With Quote
Old 01-29-2015, 02:03 PM   #12
kscop
Haysville, KS
2002 Ford Explorer XLT
 
Join Date: Dec 2014
Posts: 5

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 0 Post(s)
Older thread but I came across this when dealing with my LH Valve cover oil leak.
My manual says to remove the EGR Tube at the EGR valve and doesn't indicate that I need to remove it at the manifold. (2002 Explorer XLT 4.0)

That being said, I can't get the nut loose at the EGR valve; no amount of penetrating oil has helped and I'm a little nervous about using a torch in that location. So; what about just unbolting the EGR valve? I'd have to replace the EGR gasket but that isn't too bad.

Short of all that, I'm considering paying someone for the hassle..

Thoughts?
kscop is offline   Reply With Quote
Old 01-29-2015, 02:17 PM   #13
Tech By Trade
Your mom's house
07 Sport Trac
 
Join Date: May 2012
Posts: 741

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 90 Post(s)
You need to loosen it to turn the egr tube out of the way so you can get the cover off. I wouldn't heat it, PB Blaster and a wrench through the wheel well.




__________________
Bought a Sport Trac, Biggest pile of junk I have ever owned. I plan on letting everyone know about it.
Tech By Trade is offline   Reply With Quote
Old 01-29-2015, 02:43 PM   #14
kscop
Haysville, KS
2002 Ford Explorer XLT
 
Join Date: Dec 2014
Posts: 5

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 0 Post(s)
It seems that if it is just taken off the valve, it would pull out and make room. Interesting that the ford service manual doesn't mention loosening the tube at the manifold. Access to the tube at the valve is easy but it is frozen solid.

I'm still wondering if just removing the valve and leaving the tubes in place would do the job. It would be much easier to remove those two bolts rather than the frozen tube nuts.
kscop is offline   Reply With Quote
Old 02-17-2015, 08:07 PM   #15
BigFellor
Shittsburgh, PA
2002 Explorer XLS
 
Join Date: Jan 2009
Posts: 64

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 8 Post(s)
Kscop, what did you end up doing with the EGR valve / tube? I'm going to be tackling this job soon.
BigFellor is offline   Reply With Quote
Old 02-18-2015, 06:43 AM   #16
kscop
Haysville, KS
2002 Ford Explorer XLT
 
Join Date: Dec 2014
Posts: 5

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 0 Post(s)
i took it to a local shop and had them replace the gasket. I didn't want to mess with it and make things worse.

I usually do all my repairs myself but I've learned that some things it just makes sense to pay someone else to do.
kscop is offline   Reply With Quote
Reply


Suggest this thread to friends:

Similar Threads
Thread Thread Starter Forum Replies Last Post
Help me please. 89 ranger Explorer & Ranger Transmissions, Transfer Cases, & Differentials 32 02-21-2013 03:51 PM
TSB's, Where to get them free? nevr1zenuf Under the Hood 16 11-15-2012 01:30 PM
Any tips on replacing valve cover gaskets on a 1990 with a 2.9L V6? DenverDude2002 Ford Ranger - Mazda B-Series Forum 0 09-04-2010 09:48 PM
Valve Gasket replacement coreman23 Stock 1991 - 1994 Explorers 20 04-19-2009 03:26 PM
Idle Air Control (IAC) Valve Replacement ExplorerDMB Under the Hood 2 06-03-2006 08:16 PM



Join the "Elite Explorers" Today!



Search Explorer Forum


Top of Page

Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump


All times are GMT -5. The time now is 04:46 AM.



US Flag
We Support Our Troops!

Explore the site!


Copyright 2015 - 1996 Rick Horwitz Photography



Ford Motor Company is not involved in the management of this site in any way.



All tips on this site are for use at your own risk and discretion.

Modifying the suspension on any vehicle will cause changes to its handling characteristics.



Vendor Tools vBulletin Plugins by Drive Thru Online, Inc.