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Old 10-29-2005, 06:16 PM
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Hole in cylinder head - ouch!

I have a '99 F-250 Super Duty (5.4L) with 263,000 miles on it. It developed a pinhole in the LS cylinder head right below the thermostat housing, causing a coolant leak. After sticking it with a screwdriver, I ended up with a 1/2" hole!! Has anyone ever encountered this? I can't even drill & tap it as it is near the top of the head where there is a bend in the casting. I really don't want to pull the head off - is there some "super epoxy that will stand up to the coolant temperature/pressure? Thanks.
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Old 10-29-2005, 06:55 PM
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Maybe get someone to Tig weld a patch on it.
I would say it was corrosion from not changing coolant ???????????
A 1/2 inch hole is to big for jb -weld
Don't forget if you have someone weld it to disconnect the battery and isolate the pcm grounds also or you will blow up the pcm.
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Old 10-29-2005, 07:22 PM
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I'll have to agree with Fortyfords. It sounds like your coolant became acidic.
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Old 11-02-2005, 10:07 PM
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OK - I went the JB Weld route. I hammered out a 1/16" piece of aluminum to fit the corners and to cover the hole by 1/2" on all sides. I sanded the area and wiped it down with acetone, then JB'd the whole thing. If this doesn't work, then I might use an expanding rubber plug. I'm afraid of what the heat might do to the head if I have it tig'd, given the thin wall thickness. I'll know by tomorrow!!
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Old 11-03-2005, 06:16 AM
dew487 dew487 is offline
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For what it's worth, I have had good luck using JB weld on my 1941 Ford 9N tractor. My cylinder block developed a 1/2" crack at the water jacket. I ground v-groove at the crack and applied JB weld. It's held up for 3 years now... Hope it works for you.
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Old 11-06-2005, 08:24 PM
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All is well with the repair. I have about 50 miles on it with no signs of leakage. While I had the opportunity, I replaced the thermostat (original!!), o-ring, tensioner bearing (got it at Grainger for $6.76), belt & coolant. My owner's manual says "if it has orange coolant, use the long-life stuff; if it has green coolant, use the regular stuff" (not verbatim). I asked my local dealer and they said the same thing. GAR! Being that my coolant was orangish-green, I flushed the whole thing and put in the green stuff. I'm keeping my fingers crossed!!
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Old 11-06-2005, 10:09 PM
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I heard about this as a known issue... coolant flow past that point erodes the metal, and it leaks.

I have NO idea if there is a fix or updated head, I only know what I've read on this site

art k.
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Old 11-18-2005, 03:11 PM
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How is your repair holding up? Interested in knowing!
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Old 11-18-2005, 06:51 PM
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I had this happen on my 99 V10. Ford repaired using a sleeve and epoxy in the coolent passage. There were casting issues on the heads.
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Old 11-18-2005, 07:24 PM
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Quote:
Originally Posted by texcan
How is your repair holding up? Interested in knowing!
So far, so good! I put around 300 miles on it with some heavy hauling and no leaks!! I went bananas preparing the surface, which I guess paid off. I have some pictures of it and I'll have them up here as soon as I remember how to do it! A while ago, I repaired a broken 442 emblem stud with JB Weld (then threaded it with the speed nut!) and have sworn by it ever since. It has a working temperature of 600 degrees F, so 200 degrees F is a walk in the park.

Bear1911 - Is the sleeve to which you are referring a V10-specific item? Would one be able to get this right from Ford parts?

Brad
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Old 11-18-2005, 07:34 PM
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You can never prepare the surface too much - unless, of course, you break through to the other side
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Old 11-18-2005, 09:37 PM
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Quote:
Originally Posted by rocketman442
So far, so good! I put around 300 miles on it with some heavy hauling and no leaks!! I went bananas preparing the surface, which I guess paid off. I have some pictures of it and I'll have them up here as soon as I remember how to do it! A while ago, I repaired a broken 442 emblem stud with JB Weld (then threaded it with the speed nut!) and have sworn by it ever since. It has a working temperature of 600 degrees F, so 200 degrees F is a walk in the park.

Bear1911 - Is the sleeve to which you are referring a V10-specific item? Would one be able to get this right from Ford parts?

Brad
I don't know if it is specific to the V10, the shop manager said this was a known issue with the heads, so my guess is that it could have affected the v8 also. It was warranty work. I do not have a part number.
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Old 11-20-2005, 07:30 PM
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Here are the pics. Unfortunately, I took the picture of the actual hole with my phone.

http://img26.imageshack.us/img26/5316/dsc015443vn.jpg

http://img504.imageshack.us/img504/1544/dsc015461kq.jpg

http://img469.imageshack.us/img469/4538/dsc014091rg.jpg

http://img469.imageshack.us/img469/259/dsc013951hb.jpg

Images changed to links (it's a little nicer for the dial-up users. -Beast12

Last edited by Beast12; 11-20-2005 at 08:14 PM.
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Old 10-05-2008, 03:13 PM
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Hole in cylinder head update

Well, it's been almost 3 years and 13,000 miles since fixing my cylinder head with J-B Weld and it's holding up great! This stuff is unbelievable!!
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Old 10-05-2008, 03:36 PM
tac53parsons tac53parsons is offline
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Thats crazy!!! My truck has 130,000 on it. I hope mine lasts as long as yours. What kind of repairs have you had to do? Transmission?
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Old 10-05-2008, 03:36 PM
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