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Inside Sealing Ford 4 0L 244 OHV V6 Who For shop owners and technicians What Tips for engine sealing repairs Where Visit www felpro only com for more information Why Leverage the expertise of Federal Mogul s Fel Pro engineering team to grow your engine sealing business Highlights Intake manifold gasket selection and installation Valve cover sealing Head gasket selection Rear main sealing solution With some 2 million units registered in North America Ford s 4 0L truck engine offers a sizeable market for rebuilders Just think of all of those Explorers purchased in the mid 1990s a large percentage of these engines are surely in need of repair Known in some circles as the Cologne V6 it is manufactured in Cologne Germany this engine platform dates back to the late 1960s and early 70 when it was introduced in 1 8L form As the engine grew over the years to 2 0L 2 3L 2 8L and 2 9L Ford applied the platform with varying degrees of success to such models as the Capri Mustang Merkur Scorpio and Ranger The automaker effectively maxed out the block in its current form as a 4 0L truck engine in 1990 Ford continued to tweak the 4 0L over the next decade introducing enhanced piston configurations rods cams and cylinder heads It is not advisable to interchange heads from one vintage of this engine to another unless you are certain that the combustion chamber shape is compatible with the block Sealing the Ford 4 0L truck engine is a fairly straightforward job Be sure to update the engine with newer technologies representing more modern gasket materials and designs for intake manifold valve cover and rear main seal repairs These premium solutions are available from Fel Pro Common Leaks The most commonly encountered sealing needs on Ford 4 0L truck engines are 1 head gasket replacement 2 intake manifold leaks 3 valve cover leaks and 4 rear main seal leaks Fel Pro Solutions 1 PermaTorque head gaskets 2 PermaDryPlus intake manifold gasket sets 3 PermaDryPlus valve cover gasket sets 4 PTFE rear main seal set Numbers Alone Make Ford s Cologne V6 a Rebuilder s Dream Ford 4 0L Truck Engine Engine Models Engines in Service 4 0L 244 OHV V6 1990 01 VIN X 2 0 Million Applications Explorer Ranger Aerostar Mazda Navajo and B4000 FPO EOM 154 www felpro only com 1 Sealing Repair Tips Intake Manifold Sealing Fel Pro offers an innovative solution to issues related to the OE style intake manifold gaskets used on Ford 4 0L truck engines The OE gasket for model years 1990 95 utilizes a composite material with a non rigid molded rubber end seal In 1996 the OE design changed to a steel carrier with the same floppy molded rubber end seal This molded rubber section is susceptible to splitting if over compressed or misaligned In addition the OE design should not be used on heads that have been remachined as the change in head to manifold geometry can cause leaks at the end seal Another less serious issue related to the OE part is its valley pan design which requires separate part numbers for the left and right hand sides Fel Pro engineers developed a premium PermaDryPlus intake manifold gasket that eliminates these issues The Fel Pro gasket features a robust aluminized steel carrier encapsulated in Federal Mogul s proprietary FKM rubber which is resistant to all engine fluids To adjust for machined surfaces the PermaDryPlus part does not include the molded rubber end seal used in the OE part Rather the technician simply needs to create the end seal with RTV The PermaDryPlus gasket featuring a universal design for the right and left sides is Fel Pro engineers developed the PermaDryPlus intake manifold gasket left to address the unique challenges of the aftermarket service environment This exclusive Fel Pro solution features a robust aluminized steel carrier encapsulated in a proprietary FKM rubber that resists all engine fluids Important note To adjust for machined surfaces the PermaDryPlus gasket eliminates the floppy molded rubber end seal utilized in the OE gasket To create the end seal the technician simply applies RTV right 2 Only Fel Pro offers 100 application specific sealing solution components for Ford 4 0L truck engines Each Fel Pro gasket and seal for this application features the best material and design for the aftermarket repair environment Ford 4 0L Parts VIN X Parts Check Fuel System Fuel Injector O Ring Sets Throttle Body Gaskets Leak Repair Drain Plug Gasket Intake Manifold Gasket Sets Oil Filter Adapter Gasket Oil Pan Gasket Sets Plenum Gasket Sets Timing Cover Sets Timing Sets w Sleeve Tool Valve Cover Gasket Sets Cooling System Water Outlet Gasket Water Pump Gasket Engine Repair Conversion Gasket Sets Crankshaft Repair Seal Sets Sleeve Tool Head Bolt Sets Head Gaskets Head Gasket Sets HST Technology Head Set Head Installation Sets Valve Stem Seal Set Exhaust System EGR Gasket Exhaust Manifold Gasket Sets Exhaust Pipe Gaskets Repair Type Repair Type Premium one piece PTFE seal available Premium seal material design available Premium PermaDryPlus gaskets available Includes Severe Duty head gaskets and PermaDryPlus intake manifold and valve cover gaskets continued on next page Sealing Repair Tips continued offered in complete intake manifold repair sets 1990 97 p n MS98005T 1998 01 p n MS98006T These sets also include PermaDryPlus valve cover gaskets Valve Cover Sealing This engine platform is one of the last to use cork rubber technology to seal the valve covers The problem with cork rubber of course is that it has a finite service life often becoming brittle or saturated with age and leading to compression loss The Fel Pro brand offers a much better solution a PermaDryPlus valve cover gasket utilizing a plastic carrier with multiple silicone rubber sealing beads to accommodate any surface or flange imperfections One highly unique design feature demonstrating Fel Pro s commitment to problem solving technologies is a carrier joint that allows the gasket to flex so it can accommodate mismatched joints The PermaDryPlus gasket also features integral torque limiters to prevent damage And better yet the temperature resistant nylon carrier construction will last as much as three times longer than conventional cork rubber Crankshaft Sealing Good news and bad Correctly installing conventional rear main bearing seals on this Ford engine can be difficult In particular model years 1995 01 require the use of a wear sleeve and installation tool when using a conventional seal A better choice is the Fel Pro PTFE one piece rear main seal p n BS40647 which eliminates the need for a wear sleeve and special installation tool But remember always install PTFE seals dry Oil Pan Sealing AERA reports that oil pan re sealing can be problematic on this engine platform To ensure a tight trouble free seal follow these recommendations 1 Use Loctite 515 sealer or equivalent to fill the cavities between the block and rear main cap for the wedge seal 2 Place a 1 8 in bead of Loctite 598 sealer on the four corners of the oil pan and install the oil pan gasket 3 Place a 1 8 in bead of Loctite 598 on both ends of the block joint areas then set the oil pan in place over the four studs and snug up the bolts 4 Align the oil pan within 010 in of the rear block face and torque the pan bolts to 5 7 ft lbs Join the Community of Sealing Professionals Learn about the latest Fel Pro sealing innovations for today s engines Access and download technical service bulletins and newsletters Meet top racing engine builders and learn why they re Fel Pro Only Share your experiences with engine experts across North America www felpro only com 3 OE style valve cover gasket Fel Pro PermaDryPlus valve cover gasket When re installing the oil pan use a straightedge to make sure the pan is correctly aligned with the block
