1993 4.0L Aerostar is leaking coolant from the head gaskets.

[DET17]

I've owned my 2 tone blue XLT Aerostar since Nov. 94, and she's got 194K on the clock. The old truck has been weeping coolant onto my driveway....I thought it might just be a heater core slowly failing. However after an oil change yesterday, I lay under the beast with it idling, and I am seeing slight coolant weeping from the head/head gasket joint. This is slowly weeping down both sides of the 4.0L block, and pooling on the bottom of the oil land.

Well, I have to believe the head gaskets have just aged out and need replaced. Of course the rear main oil seal has been leaking, and possibly the front seal behind the HB as well (both original).

I understand the difficulty of removing the powerplant from the Aerostar...I'll likely hire it out, as I don't yet have a lift in my workshop. I can't imagine anyone could pull those heads with the engine still installed!

Any recommendations for crate engines? See a couple on eBay.....my local rebuilder wants 3.5 to 4K for a complete TOTAL overhaul. The crate motors are closer to 2K.

Comments?

 

[BrooklynBay]

My 1988 van with a 3.0L once had a similar issue, and it was a broken bolt on the engine. Check the bolts to see if they are tight, and the freeze plugs. The cost of a new engine is more than the value of the van. You could rebuild the old engine yourself or look for a junkyard engine for a few hundred with low mileage.

 

[rv4fun]

Why not watch Craig's List in your area for a replacement Aerostar. You can more than likely buy another one a lot cheaper than a new engine.

 

[DET17]

My 1988 van with a 3.0L once had a similar issue, and it was a broken bolt on the engine. Check the bolts to see if they are tight, and the freeze plugs. The cost of a new engine is more than the value of the van. You could rebuild the old engine yourself or look for a junkyard engine for a few hundred with low mileage.

But does the 4.0L engine have this issue? I guess I'll Google and see what I can find. Sure not freeze plugs, I can see 5 of the 6 on the 4.0 and the weeping is coming from the deck junction where the gasket lives.

I'm well aware of the value vs. the cost I've already done enough OTHER repair work to this Van (new A4LD among other suspension rebuilds) that I plant to run it into the ground.

I certainly am looking for a gently used 4.0L, but that will be a tough find after all these years! If I can't find a good core, then I might just have this 4.0L pulled for a resealing, new front/real oil seals, refurbish the the heads, new HG and try to rock it another 100K.

 

[rv4fun]

I pretty sure I've read where the 4.0L has problems with leaking intake manifolds now and then.

How to: Aero 3L head gasket pics - in vehicle

 

[DET17]

I pretty sure I've read where the 4.0L has problems with leaking intake manifolds now and then.

How to: Aero 3L head gasket pics - in vehicle

I've heard about those stinking gaskets as well....believe we will take care of it at the same time as my cracked cylinder heads. Google searches show the 90-94 4.0L is very prone to head cracking failure. Now if I can just find a FORD lover to drop that engine for me.....

 

[Jose A.]

the 4.0 is prone for those kinds of head problems, but if it is an issue of just replacing the head gaskets, it can be done with the engine in place. Not a piece of cake, but doable.