4.0 SOHC Tapping noise w/video

[shelbygt]

Got it home. The engine temp said it was cool, but the motor was still warm. I let it run with the rad cap off (temp gauge said it was still very cool) and I was going to top it off and it started pumping water out then a rush of hot water out of the radiator. I mixed something up! The thermostat I got new from Ford, so there was only one o-ring in there from Ford. I have the thermostat in right, but I just couldn't remember it the o-ring went on top or under the thermostat.

 

[shelbygt]

I can't catch a break!

So I pulled the upper intake and thermostat back out and the o-ring was on the top of the thermostat (which I believe is correct) and I found that the just over 1 year old Ford thermostat is cracked along the top almost all the way through in a "t" like pattern.

I also removed the whole t-stat housing to check for issues and found some tiny pieces of blue shop paper towel inside. I must have left a piece of towel inside a passage at some point of the month long project (so stupid, stupid).
But i drove the truck all last week 2-300 miles and never had a cooling problem. Yet after I removed the thermostat today and cleaned the o-ring and put it back together, I now have problems. I can't imagine it is a coincidence. The shop towel I hope will just disintegrate and not cause any issues, I would think that if pieces of solid scale can float around the cooling system and not cause issues, that this shouldn't.

Would this t-stat sticking cause the problem I am having?

I noticed after I filled the radiator today (stone cold) and I started the truck coolant was immediately slowly flowing out of the radiator( not like when the head was leaking). but a steady flow.

Also if this bits of paper towel is an issue, do they make a flush that will eat it up?

I am cursed my friends!

 

[BobWiersema]

You may want to pull the radiator and back flush it. If the rag wound up in there it should float out. Lay the radiator on the ground with the hose connections up and force water through the bottom connector.

You are on an amazing streak of bad luck. Dont buy any lotto tickets or go to Vegas until this passes.

 

[ranger7ltr]

You have to be at the end of issues with this engine...

I have followed your progress and really hope this is the end to the issues you have with your truck... My issues seem minor compared to yours yet I still began my own project...

Some of my findings were unreal... At least to me...

Here's wishing you better luck in the future...

 

[shelbygt]

It looks like the cooling issue is gone. Drove it about 25 miles, no problem. I actually filled the block through the thermostat opening, to make sure that the block was filled with water, so as Dale suggested, it probably had an air pocket in the cooling system. I have to drain the radiator tomorrow and add antifreeze, hopefully besides oil changes I am done for a while. Live and learn!
Thanks again all,
Dave

 

[BobWiersema]

Did you replace that damaged thermostat?

 

[shelbygt]

Did you replace that damaged thermostat?

Yes Bob I did, along with the o-ring. I believe that has stopped leaking as well!

 

[fxerider76]

I just got my '02 4.0 Explorer engine back together after having a head repaired. The car has been sitting since April. It cranks, has spark, I pushed the fuel pump reset button, but it doesn't fire.

Any ideas out there? I could use the help.

Bob

 

[drothgeb]

Glad you got everything figured out ShelbyGT. After reading through your thread I just noticed that my thermostat never had an O-Ring on it...It was leaking coolant about 2-3 months ago and I ended up just using red RTV to seal it and the leaking is gone...Was this a permanent fix or am I looking for problems in the future now? For the record I let the dry really well before starting up the engine.