Hi again (92 5L),

So I replaced the valve cover gaskets and the exhaust with some help from you all (well, and a saws-all) but I still have problems.

I am still leaking oil from somewhere. It is coming from the passenger side, and I am guessing burning up on the exhaust. When I originally had it diagnosed (still a novice- needed to know what problem was) he said I had oil coming from valve cover gaskets, lower intake manifold and rear seal. I have ruled out doing rear seal, since I do not have the materials to drop tranny (that's what I would have to do, right) So either I am having PCV valve issues, I need to redo the valve cover gaskets again, or its lower intake, right? Is it possible I have too much oil in? would this cause a leak? Is there a break in period for cork gaskets where they are more likely to leak? I also noticed that the valve covers were not doing so well at the contact surface. How much defect does the cork correct? I literally had drops by my oil pan.

I also am smelling gas, so I read up on that, and I should STOP running the truck post-haste and smell oil- will do. If it smells like gas I should look at fuel pressure reg-right? I figure I should clean TB while I am there?

I also smelled something else. Kind of hard to explain. It almost smelled like when you use a table saw on wood. Dont think it was rubber. Anything on that?

I was getting a nasty headache while driving- is this consistent with anything? I have to say that my baby was crapped on before I got it. It was put through 2 trees and a fence. (Already did most of front end- ball joints, tie rods, etc.) So assume the worst.

 

By 92 the OEM valve cover gaskets were metal frames with a rubber core that work beautifuly and should only need to be retorqued occassionally. However, if yours doesn't have them, I'd go seek out a rubber set or even spend the extra $$$ and get an OEM set from Ford. The cork will work but does tend to vitrify (harden and brittle) rather quickly. If the valve cover flanges are bent from overtorquing or prying at old gasket material you will need to put on your blacksmith attire and start flattening the flanges where they meet the mating surfaces of the cylinder heads. Make certian you removed any old gasket material as well as imperfections in the mating surfaces will be prone to leaks.

Now with a rear main leaking and the OEM exhaust system you could be getting some oil dropping on the section of the Y-pipe that runs under the engine from the driver's side as thats very near the location that the rear main would leak.

With the fuel odor certainly be extremely careful. If you can smell it then fumes are present and are more flammable than the liquid gasoline. The FPR is on the fuel rail near the driver's rear corner of the engine. If you pull the vacuum line to it and there is fuel inside its gone south on you. Check the connections at the rail from the braided lines coming up from the frame. Wouldn't be a bad idea to check the filter as well. Its on the driver's side frame rail just about where the driver's seat is located. Remember to release fuel system pressure when removing or replaceing fuel system components.

Ok, if you have an oil leak from the lower intake you've got worse problems than a leak. There are no oil galleys in the intake at all. There ARE two COOLANT crossovers in the lower intake and the smell you describe could be burning coolant. The only real fix is to pull the lower intake and replace the intake-to-cylinderhead gaskets. Drain the cooling system first.

Lastly, check the exhaust system for leaks and NEVER drive with just the tailgate glass down (always open at least one of the front two windows to create a cross-draft). If you are getting a headache while driving you are inhaling too much carbon monoxide.

 

Take a good look at your oil pan gasket, they are known to squeeze out from between the pan and block or in my case it was ripped. It can look like a rear main seal leaking. If it is your pan gasket replace it with one that has the steel reinforcement made in the gasket Ford sells a nice pan gasket.

 

Thanks guys. I double checked the diagnosis from the mechanic and it does say lower intake, but I have had too many people tell me too much fiction. I will take your word about that.

The valve covers... If I recall it looked as if the 'rubber core' had either corroded or just chipped off in a few places. I wouldn't say it was bent. I was just wondering how much inperfections were passable.

The fuel rail is the chrome thing under the upper intake right?

In terms of the oil pan gasket, I think you are right. I will take care of that. There are a dozen or so posts on that; I will spare you guys the pain of holding my hand through another repair. I spent most of yesterday sticking to the man by reading old posts all day long.

Thanks again Greystreak and XLT

 

Sorry Greystreak, but I have to jump in here. It IS the fumes that ignite, NOT the actual liquid. I have been working with fuel in the Navy Reserves for 10 years now, and it is a common misconception that it is the liquid that burns. That is why they tel you NOT to get back into your vehicle when you are filling it up. Static electricity is a killer at the fuel pump. Just think back to those hot summer days when you look at the next pump and can see the vapors flowing away from the open filler tube. That's why it is recommended that you fill in the evenings vice the daytime in the summer.

 

Checked dip stick and it does smell a little like gas, but I could be talking myself into that. The vacuum hose to the FPR is clean and doesnt even smell like gas.

I did notice that the oil on the dip stick is well above the "full" line. Is this an issue?

I'll be in and out sorting out the roladex of issues on "foley".

 

What is a good way to check the exhaust? My headers look like they have been through war. There also is a hole in the firewall from something the knucklehead that had Foley before me made. This would explain the headaches I think. Maybe I will work on steering column today. O boy.

 

bjbmogolo, you are having the same leak as I have currently. It's leaking out the passenger side somewhere. I saw that it was coming down the block out of an overtorqued bolt on the valve cover so I fixed that. Put it back together and it is still there. It looked like it was coming out of the crease between the lower intake and the block, where the knock sensor is located. I also think that my rear main is leaking but its hard to tell. The oil likes to collect in that location no matter where the leak is coming from.

The best way to find an oil leak is to clean the engine really good with a de-greaser and then run it a bit to get the leak going but not blown all over and then look at it really good to see if you can locate it.

I haven't found mine yet, I plan to clean it up really good and take a harder look at it over the weekend.

I keep checking my dipstick and it is always full, actually higher than the checkered area but it leaks it's a*s off all the time so I don't understand why the level isn't moving much.

If it is the rear main I planned to pull the engine just cause it will be easier and I've done that so many damn times, I can do it in my sleep now.

what are you checking your exhaust for? To see if there is a leak? You will smell the leak....well, you'd smell it if there weren't so many other things going on with your truck. I'd probably look for exhaust stains maybe, like black spots where it may be leaking. You'd also hear an exhaust leak.

 

why am i checking exhaust? Well... it was the hallucinations and violent headaches I was getting when I drove. The underside and everywhere around the engine is so coated cleaning it would take a huge effort.

When you say you can hear the exhaust- like how? From the headers to the muffler that I just replaced it is oxidized BAD, so it is really hard to tell. I had to use a saws-all to get the muffler off. Was kept by the ocean...

Getting rid of it is not an option, so I'm off to Advanced.

Anybody else reading, I was reading about the evaporative emissions system canister. Anything there for the fuel smells?

thanks again in advance!

 

I think all exhaust smells on Broncos when you onlly open the back window and nothing else. It makes you eyes water and gives you a headache.

To check if you have an exhaust leak, you'd be listening for the sound around the manifolds and along the pipes.