1999 4.0L head removal

[RussAdams]

Do I have to remove the intake manifold to remove the us driver's side head?

I removed everything down to the head today. Including the pictured rocker and push rods and head bolts and driver's side intake manifold bolts.

I have a bad leak that is not from the timing cover... I expect it to be either the head gasket and/or warped head.

 

[JoshT]

You've definitely got a big leak. Showing up that well on the crossmember, I'm surprise it isn't pretty obvious where it's coming from on the engine.

It could also be the intake itself, IIRC there is a coolant passage that passes through thefront of the intake.

In my experience, and I've done head gaskets on a 4.0 a bunch of times over the years (~7 times over 15 years, that's why I just went 5.0), the lower intake does have to come off. There are dowel pins in the block that positively locate the heads. While I haven't actually tried to pull the head with the intake in place, I'm pretty certain that the angle of the intake and the dowel pins trap the head in place.

Even if it were possible I wouldn't attempt it. The intake needs to come off to properly clean the gasket surfaces and reseal it to the head during reassembly. You are not going to get the intake to head gasket in place and sealed trying to do it with the intake in place. Either it simply wouldn't go, or you would damage the gasket leading to more leaks. If it were possible, you would potentially cause more problems than you would fix and be right back in there replacing intake gaskets.

Also, after the head is installed, you need to run a bead of sealant across the seam where the head and the block meet to seal them to the intake when it is set in palce. The sealant basically fills the small gap where the head gasket, intake gasket, and china wall gasket meet and be a source of oil leak if not done.

Sorry for making such a long response to say: Avoid the headache, pull the intake.

PS: FWIW, I'd grab a head gasket set tha tincludes all the intake gaskets, and do both heads at the same time.

 

[RussAdams]

You've definitely got a big leak. Showing up that well on the crossmember, I'm surprise it isn't pretty obvious where it's coming from

Sorry for making such a long response to say: Avoid the headache, pull the intake.

PS: FWIW, I'd grab a head gasket set tha tincludes all the intake gaskets, and do both heads at the same time.

Thank you for the thorough reply! Greatly appreciate you taking the time.

I will take your advice and pull the intake and passenger head too.

Just ordered a full gasket kit, including headbolts, from RockAuto.

After looking at the push rods and seeing the amount of wear I also ordered new lifters and push rods.

Will also replace the injectors while I'm there.

This Ranger has 240,000 miles. There was a number hand written inside the crank/timing cover. And initials hand written on the head under the valve cover. So I suspect there has been a lot of other work performed in the past.

I hope to keep it running for many more miles!

 

[RussAdams]

July 15th 2024 update:

I have both heads off today and can definitely see where the leak came from. The intake gasket at the top of the driver's head blew out.

There is also quite a bit of 'thready' garbage in the head. Hmmm.

And when I took the head off the gasket is covering SERVERAL water jacket holes. Is this normal?

 

[JoshT]

That sucks, finding what you did, I probably would have stopped at the intake gasket. Since they are off, it still wouldn't hurt to get the heads checked. If you do, see what they think about the valve stem seals, now would be the time to replace them if needed.

Yes, that is pretty normal on the water jackets.

 

[RussAdams]

That sucks, finding what you did, I probably would have stopped at the intake gasket.

I loosened the head first. Inexperienced with this engine. Lesson learned.

Since they are off, it still wouldn't hurt to get the heads checked. If you do, see what they think about the valve stem seals, now would be the time to replace them if needed."

I bought new stem seals and will replace them. The valves look very good. The push rods did not. Pretty worn so I'm replacing them and the lifters while I'm here.

Yes, that is pretty normal on the water jackets.

Wow. Why would you want to cut off half the water jacket flow?

I'm very tempted to open them up. Anyone have a photo of an OEM head gasket?

I have not opened my EngineTech gasket set yet.

Advice would be greatly appreciated!

 

[RussAdams]

Here's the enginetech headgasket:

It covers some holes too. Interesting.