I picked up a `99 F150 4.2L with 4R70 back in summer 2017. Trans was slipping but otherwise truck was in excellent shape. I let it sit up too long and fuel pump took a dump. Gas tank was completely full with some stabilizer. This did better than I had expected since only half of the gas evaporated over time. The old gas is not so nasty smelling or like I normally see. It did not turn to brown gooey sludge and varnish. There is buildup at the fuel level, but upper part of tank is not all rusted. The problem is not fuel related. Just including this in the history up to date.

The BIG problem came when I tried rotating the engine around to remove the torque converter bolts. The engine is locked up solid. I used cheater on break over bar and all it did was tighten the crank bolt. The engine has been sitting up not running for about 4 years. Everything is completely sealed and original. Air filter, exhaust system, nothing to let any more moisture in than normal.

I have a dozen old vehicles sitting around not running. Not one of them is locked up from lack of use. Most of them have not run in over a decade.

The only difference here is I did remove the trans pan a few years ago. I dont think the pump would be locked up from exposure. But right now anything is possible.

If someone has any ideas I am all ears, as Ross Perot was known to say,

 

check the oil
remove the spark plugs and see if it will turn
look down into the cylinders and see what you find
report results....

 

I did check the oil first thing It is right at full level and clean. No chance of cracked block or anything from freezing. No rust from moisture on upper part of dipstick. Will report back if anything shows on the plugs. If signs of corrosion, I will run a camera down the plug hole.

 

Things are not looking so good. After removing all 6 spark plugs I noticed signs of moisture on both front cylinders.

This is how the plugs are in the engine.

Next i stuck a camera down the cylinders. Again not what I wanted to see, obviously.



Piston is at the top. The bubbly rust is only in this one spot. Most of the cylinder is clean. Both front cylinders have rust. This is the worst in pic.

The next thing I did was a coolant pressure test. I pumped up to 10 pounds and slid a small vinyl hose in each cylinder. I was not expecting to hear a leak since it would be pushing fluid out not air hissing. The next test was using a pull rope for a lawnmower. I inserted about 3 feet in each front cylinder. After pressure testing, if there was any leakage, the nylon rope would absorb any coolant in the cylinder. But at this point nothing was found. The rope came out clean and dry.

So far, all I did was attempt to rotate engine by using a break over bar on the crankshaft bolt from underneath the truck. I had nothing to loose, so installed the battery and surprised that the engine popped loose immediately and spun over just fine. Here was the next problem found. Both right side cylinders, front and middle spit out coolant now. So I know there is most likely an intake gasket leak. The coolant was pooled up in the lower section of manifold. That is if I am thinking correctly.

I will remove the upper and lower intake manifolds and confirm what my suspicions are. Since discovering this I have read up and find the intake manifold gaskets are indeed prone to failure. If someone wants to add anything I will be forever grateful for your suggestions advice or critique.

Something I had forgotten to do was remove the break over bar with socket still on the crankshaft bolt. After bumping the engine over, I heard a clunk. Then found the big bolt laying on the floor.

 

Yeah. Not good.

If you decide to try and make the engine run again, there are some really good videos on replacing those gaskets. Here's one.

 

Thanks for the link. IF this is just caused from leaking intake gaskets like I am hoping, the engine will be running again. No sooner is that taken care of, I will be back to removing the transmission.

If the engine turns out to be junked I do have a 4.6 with 4R70 sitting in a van for a spare. I would prefer this 4.2, but not loosing out getting this truck up and running.

 

We're all in this together...

 

The early 4.2's had some problems. I don't know what the cracked lower intake manifold looks like or what it causes but it's something to be aware of. Along with the timing cover gasket problem. I know you said 99 but it's not clear if it's a model year problem or build date.

https://en.wikipedia.org/wiki/Ford_E...gine_(Canadian) (you have to click again on the "Did you mean" link even though I pasted the exact link here.)

The 4.2 L Essex has been described as one of the more reliable engines offered in the F-150 at the time, although the early engines did encounter some well-known problems.[11] All 1997–1998 engines made at the Canadian Essex plant received a bad front cover gasket.[12] Ford initially addressed this problem by using a thicker gasket for the 1999 model year and five years later, in 2004, replaced the earlier gasket with a completely redesigned part. The lower-intake manifold also had a reputation for cracking at relatively low miles.

 

My `99 4.2L has aluminum upper and lower intakes. I can see the newer plastic manifolds having a tendency of breaking. But most everything that changed over to plastic has the same problem eventually.

 

Timing cover gaskets were the prevalent issue with that engine. The 4.2 is nothing more than a bored out 3.8 and those things were notorious for this problem, timing gasket leaks down enough to make the engine overheat and that in turn takes out a head gasket or 2.

 

Back when these engines were common, most of them were taken out by bad intake gaskets, which bent a piston rod when starting up or dumping water into the cylinder while running.

Since yours was not started up, you will probably be OK if there isn't too much rust/corrosion in the cylinder.

If there is a lot of rust and corrosion, removing the head, or heads, and giving a good cleaning, will most likely remedy any problems you have,

 

I spent the afternoon working on removal of the intakes when the clouds were blocking the summer sun. There sure is a lot of hoses running all over this engine. Hope I remember where everything goes when putting the truck back together.




I presume this is a balance shaft covered in rust, If not please feel free to correct me. I dont know yet where the moisture is coming from. Will need more time to check things over tomorrow. Unless someone has seen this before and can confirm what is likely to have happened here. This has to be from coolant leak, but dont know exactly where it came in. There is discoloration in places marked. These are the areas that had leakage in cylinders on both sides. One thing I will make sure of is doing a pressure test in questionable cylinders. I want to eliminate the head gasket being a potential problem too.

 

You are correct, that is the balance shaft.

If that were my engine, I would rebuild or replace it. There is no bandaid for what I'm looking at.

 

That looks bad. I'm not sure I would pursue it any further. I don't know how many miles are on this '99 engine but a rebuilt replacement or low mileage salvage should be considered.

 

There's really not much to go on in that picture. Rust on a shaft that spins without contacting anything.

Have you checked the oil? See if the pan has water in it. It will give you an idea of the volume of the leakage.

I'd check that lower intake manifold for cracks.