Front Engine Cover Coolant Leak

[tomj76]

I have a '96 Windstar with the 3.8L v6 engine, 205k miles.

There is a coolant leak coming from behind the front engine cover. I can see the coolant path. It is a slow drip (about 1-2 drips per minute) only after it has been driven. Once the engine cools, then drip mostly stops. The amount of coolant involved is small, only an ounce or two at a time.

There is a gasket behind the front engine cover, and it's my guess that this is what is leaking. I suppose the cover is used to distribute coolant from the pump to the heads, but I don't really know.

The Ford service manual instructs to remove the engine from the vehicle in order to service this gasket. I'm not going to be able to accomplish that feat.

Has anyone serviced this gasket without removing the engine? If I can remove the water pump, power steering pump and alternator, as well as any other stuff on the front of the engine, then what should stop me from removing the front cover as well?

Also, is it possible/reasonable to use a stop leak in the coolent to repair the leak, given that such is a slow drip?

[wiswind]

FORD has revised the repair instructions and you don't have to remove the engine to do the repair.....That is the good news.

HOWEVER, it is a MAJOR job!......which is the bad news.
You can read up on it for FREE at AutoZone's website under vehicle specific repair information.
It is not for the faint at heart......as you have to remove and re-install a lot of stuff....and need to have the correct tools to do these things.
And...although you don't have to remove the engine....you do remove the mounting at that end of the engine.....and have to move the engine some......meaning that you have to support the engine.

My '96 had a very slight seapage at that location some years ago.....not enough to put any drops on the ground.
I put Bar's Stop Leak into the coolant, and it DID solve the problem
I am a good 6+ years and well over 100K miles on that repair......

You DO need to be most concerned about coolant leaking INTO the engine.....into the motor oil.
So it would be a good idea to put the stop leak into the cooling system.
Then, about 1 week later, change the engine oil.
Pay CLOSE attention to the coolant level.....and if it is still using any coolant, I would have a sample of the engine oil tested.
You can get information and a free sample kit from www.blackstone-labs.com

The Bar's Stop Leak will NOT clog your heater core, etc if used correctly.
It did NOT solve my leaking lower intake manifold gaskets, although it did slow the leak....maybe even stop it for a month MAX.
Now, a year and a half after the lower intake manifold gasket repair, I do not use any coolant.

[tomj76]

Thanks for the reply. Even with this leak it's not loosing coolant at any appreciable rate. Given your experience with the stop leak, it sounds like the best bet.

Thanks for the reply.

[road_rascal]

Yes- you want to make absolutely sure there is NO coolant in the engine. My '96's engine seized 75 miles after Ford replaced a leaking headgasket (due to coolant mixing with the oil).

[wiswind]

OUCH!!!
The factory instructions say to change the engine oil and filter.
If that was NOT listed on the repair invoice....then they are responsible for the failure.

I know from personal experience......even after careful draining of the coolant......when I lifted the lower intake manifold up off the engine....I heard a whoosh! as soon as I broke the gasket seal.....as the remaining coolant that was trapped in there ran down into the crankcase.

They have to remove the lower intake manifold to do the head gasket repair.....and the factory instructions say to use NEW lower intake manifold gaskets (they are NOT re-useable).
So they should have been good......and if not....covered by the repair warranty.

This is a good case for having access to factory repair information, even when having the vehicle serviced for you.
There are repairs that I just do not do.....but when the shop tells me what needs to be done....I am right onto AlldataDIY to read over what is involved.

[tomj76]

I could only put about 1/4 of the bottle in, but even that seems to have been enough to cure the leakage. I'll check out the engine oil as mentioned.