Hey guys I am new here, but have been lurking for some time now reading alot of the threads and getting alot of useful information here on the forum. I have even used some of the "mods" here on my 1998 4x4 4.6 Expedition, such as the "gotts air intake mod" and have also trouble shot things, cleaned sensors and etc. I recently began hearing a noise coming from the passenger side that would get faster as I increased my throttle. Reading the threads I figured, it would be an exaust manifold gasket leak or at worst a bad manifold. I took it to my mechanic and he found two studs broken and drilled them out, replaced with all new ones and replaced the gasket. Still just as loud. Well we ordered a manifold and installed it with new gasket but it still was as loud as before. So he put a square on the head and he told me the heads are warped and it will need to be rebuilt. My question is how much does this normally cost labor and parts. I have used this guy before and trust him, but was just trying to get a feel for what others have found. I also have a leaking freeze plug and a couple other small leaks, and he suggested, I just buy a used 4.6 and he would swap it out for me, as it would cost about the same. Any insight would be much appreciated.

 

Hey Rick welcome.

How many miles on your expy? How long do you plan to keep it? These are just a couple questions I'd be asking myself before deciding on a course of action.

If I were going to sell soon, I wouldn't spend a cent and sell as is. If I were going to keep it for many years to come, I'd invest in a new engine rather than swapping in something that's been used (and possibly abused).

 

In my opinion, it would be odd for the heads to be warped on the exhaust manifold side. Have you narrowed the noise down to an exhaust leak? How loud is it? You haven't blown a spark plug out have you? Just some things to think about.

 

Thanks, I do plan on keeping it for awhile. I am just trying to weigh my options. I did think it was a spark plug at first, but ruled that out. The cfost of a new engine vs. a used one is double, and I just can't justify the cost at this time.
Oops, forgot to add that there are 112,000 miles on the od.

 

"I took it to my mechanic and he found two studs broken and drilled them out, replaced with all new ones and replaced the gasket. Still just as loud. Well we ordered a manifold and installed it with new gasket but it still was as loud as before. So he put a square on the head"

That would have been what to do BEFORE tossing a manifold on. BTW, I'd try double gaskets for some enhanced "crushability" to conform to any warped surfaces, or look into gasket materials that conform better.

 

^^interesting^^ I just might try that. Any suggestions on what material for the gaskets. and thanks for the replies. I do agree about checking the heads before putting on the gaskets. I didn't want to call him a part swapper though (hehe) He didn't charge me for the extra time spent on labor. He is an honest guy, that I have used in the past.

 

I've done this on various used cars, but not specifically with that Ford. I'd compare available gaskets and look for something with bulk as opposed to steel shim.

BTW, high temp RTV applied in a VERY thin coat to the gasket can help seal exhaust systems.

 

Anyone ever try the remflex gaskets?

 

I have heard very good things about Fel Pro gaskets. Lots of Mustang guys swear by them.