I have a 1996 Explorer with the 4.0 motor. Today coolant started running out between the Freon compressor and the block at the front left corner. I cant see behind the compressor. Compressor hose seems to be short and stiff so removal of compressor is questionable ? I look from the front and does not seem to be thermostat or temp sensors. It appears to be behind that, like the bottom of intake manifold ? I wonder if there is a known problem in this area or how to go about disassembly. Don't want to take off compressor and steering pump if the problem is intake manifold. Anyone worked in this area ? Have a problem ? Where to start disassembly to look ?

 

Are you able to see the bottom of the water pump to confirm it's not the water pump that's leaking? From your description it sounds too far forward to be from a freeze plug location, but it also sounds possibly too far toward the corner to be the water pump, although I'd suggest confirming that before pulling the intake.

-Rod

 

Steve, I had the same issue with my '96 Explorer 4.0l. I could have swore it was coming from the intake gasket. After replacing the gasket I had the same leak. I'm thinking now it must have been a cracked intake. I ended up selling the vehicle so I will never know for sure. Make sure you inspected yours closely if you decide to remove it. Good luck!

 

this is the "spare" truck and I will not get to it until Saturday when sun is up. Im thinking to pull the bolts on the compressor / maybe steering pump and not remove, but push 1-2 inches outward toward the fender and try to take a better look. Might have to run a minute or two without fan belt, or maybe I can just pressurize the cooling system and see it run. This was not a small leak ! Would like to think it something simple like the pump, but it was way to the outside and close to the compressor... unless its just a blind spot and I cant tell right now.

 

im now wondering if the leak is behind the front cover, where it bolts to the block.. there is a water passage on each side, see below........... will know more saturday

 

well, I pulled the compressor and steering pump loose and tied toward the left fender. Took off the air inlet and controls, the poured water in the radiator. Leak is above the front cover and back a couple inches. Looked like the intake manifold gasket to the head. Sprays downward and runs off the front cover to the left.... Pulled the alternator , coil, injector fuel plate ......... intake manifold is screwed to the head and BOTH valve covers set 1/2 inch over the manifold and seal to it... move more stuff around to get both valve covers off.... finally to the manifold.. Bolts are about 2-3 ft pounds of torque, very loose. Got the intake off and gasket is blown out. Cleaned everything up. went to Auto Zone and new gasket set is $90. about a dozen gaskets in the set... Intake and fuel plate reinstalled. Passenger valve cover back on... About 4.5 hours to disassemble .. about 1 hour on reassembly so far.. hopefully finish tomorrow.

 

my 96 was leaking coolant like mad and it was te *heater control valve*(?) standing facing te grill, that was to my left. It was an easy swap...cheap too.