I'm not able to comment on the Fel-Pro upper intake gasket, since I went with the Ford O-rings.

Are you also planning on replacing the fuel rail gasket on your '97?

 

Yes, I'll be doing the fuel rail gasket as well. Now here's a curve ball. The Fel Pro VS50368T gasket listed on Autozone.com now says that it "will not fit 96 and upper models": http://www.autozone.com/R,APP743451/...ductDetail.htm

I wonder if they changed something and I'll now be out of luck for my '97.

 

I'm not sure. Maybe it has something to do with differences in the upper intake. I think right around '95 or '96 is when it went from metal to plastic on the 4.0L OHV. Someone correct me if I am wrong on that.

 

Well, Rockledge, this is the same part you successfully used on your '98 4.0L. If it doesn't work for "96 and upper models" that would imply that it wouldn't work properly on your '98. Clearly that's not the case, so unless they made changes to the gasket recently, I'm more inclined to believe that it's a typo. When you purchased yours a few years back, did you purchase each Fel Pro valve cover gasket separately, or was it still a package of two like it is now? I guess I'll find out tomorrow if it'll work properly.

 

I thought you (and Autozone) were talking about the fuel rail gasket, which I did not replace. I only replaced the upper and the lower intake gaskets and valve cover gaskets on my '98.

Back when I did the repair, the fuel rail gasket was not a part of the the Fel Pro VS50368T gasket set; in my case, there were only two valve cover gaskets (R+L) in the box, and that was all.

 

I know the kit I bought from advance (felpro perma dry plus) contained the gaskets for the fuel rail, and then it contained 3 (or maybe 6) rubber rings that were supposed to go on the intake manifold/fuel rail as a gasket somewhere. But my old ones were the fiber gaskets (which is what I used), so I would assume that on the 96 and up they used the rubber ones with the plastic manifold, and hence the part number difference.

 

Well, the job is done. I had the dreaded fuel rail gasket problem. You can see in the images below where the gasket was sucked into the rear intake.



Underside of fuel rail


I used the Fel Pro VS50368T valve cover gaskets even though Autozone.com now says they "will not fit 1996 and upper models." They were the same gaskets Rockledge used on his '98 and they worked just fine on my '97. I also thought that the additional gasket that came with the package was a new-fangled upper intake gasket to replace the 3 large black o-rings. I was mistaken. It is actually the fuel rail gasket and looks to be an exact duplicate of the OEM version I put on. Anyone need a Fel Pro fuel rail gasket?

Thanks for the great write up, Rockledge. It was a big help. More pictures would be great, of course, and I think the addition of TSB 98-6-8 (Fuel Rail Gasket) would be another improvement.

Another successful job and probably about an $800 savings.

 

Glad to hear you fixed her up. Nice pics of the failed fuel rail gasket, too.

 

P.S. The fuel rail gasket TSB (98-6-8) can now be found at the end of the writeup. Thanks for the suggestion Bob.

Replacing Ford 4.0L Upper Engine Gaskets

 

my failed fuel-rail gasket looked similar, both ends of mine (front & rear) were pulled in though. been running great since then, also doesnt run as warm. vac leak=lean burn= runs warmer.

 

My 1997 4.0 suffered a total failure of the intake to head coolant gasket. The whole front side of the gasket blew out toward the front of the truck in a spray of antifreeze. I'd post a pic but don't know how on this site. Says at the bottom I can't post attachments. That mean pics?

 

I need to mention the super "How-to" of Rockledge's on replacing the gaskets. This is a super tutorial! THANKS,Rockledge!

 

All went well but I now have a 1401 High Voltage code.

 

Check that you properly hooked up the DPFE sensor hoses and harness connector.

 

Will do this evening. Got a new DPFE just in case. Thanks for the tutorial! It was a great help. I'm and old hand at wrenching,but these loaded with electronics engines are a whole different world from my 351 Cleveland. Well,my straight 6 Supra turbo is in this electronic realm, I guess. Off the the garage! WML!