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Car Forum / Ford / Ford Cars / November 2004

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95 Aerostar - Water blowout into bell-housing, hidden freeze plug, head gasket or cracked block?  Urgent, watching!

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Diogenes - 11 Oct 2004 02:36 GMT
Please!  Last week engine overheated when heater control valve fractured.
Got very hot without hot thermostat, as water blew out before boiling.  May
not have waited long enough before adding water.  Could have cracked block.
Today, lost water again.  All external freeze plugs intact and engine dry.
Water drained from bottom of transmission bell-housing.  No water in oil.
Is there a hidden freeze plug in housing area?   Two rear freeze plugs are
visible above housing, intact.   I didn't think head gasket extended into
housing.   If only possible problems are head gasket and/or cracked block,
may not be cost productive repair.   Any chance anything else could blow hot
water into bell-housing?
I got a ride to work for Monday.   Tuesday must repair or buy used
replacement.  Money is a real issue, but time is more.   Can't spend time
and money to repair if long and costly.  No spare car.  Other repair
problems are likely due at 150,000+ miles.
I am monitoring for your repl(ies).  Can't find my Motor's manual.   Please!
Backyard Mechanic - 11 Oct 2004 03:50 GMT
There are usually two back there on a v-block... but that doesnt mean that's
your problem... and if it was a drastic enough shock to loosen a freeze plug
it may also have put a hairline crack in one or more places.

Your choice.

> Please!  Last week engine overheated when heater control valve
> fractured. Got very hot without hot thermostat, as water blew out before
[quoted text clipped - 12 lines]
> I am monitoring for your repl(ies).  Can't find my Motor's manual.  
> Please!
Diogenes - 11 Oct 2004 12:20 GMT
Thank you for your prompt reply!

This is the smaller 3.0 engine, and two rear freeze plugs are visible,
intact, above the top edge of the bell-housing, one on each side of back
wall of the block.    Are there any freeze plugs lower on the rear of the
block, placing it or them in the housing?

> There are usually two back there on a v-block... but that doesn't mean
> that's
[quoted text clipped - 20 lines]
>> I am monitoring for your repl(ies).  Can't find my Motor's manual.
>> Please!
Diogenes - 12 Oct 2004 01:47 GMT
I have found the answer!  Two regular and one timing chain freeze plugs,
behind the flywheel.   $250.00 to replace all rear plugs with new brass
plugs.   Hope that is only problem.  Thanks, folks!

> Thank you for your prompt reply!
>
[quoted text clipped - 27 lines]
>>> I am monitoring for your repl(ies).  Can't find my Motor's manual.
>>> Please!
mhopper - 04 Nov 2004 21:56 GMT
Thanks for the info it was helpful.  I also had antifreeze leaking from the
bellhousing area of my 95 Aerostar.  It was leaking such that as I added
water to the radiator, it was dripping out of the area of the bellhousing
when the van was not even running.  The funny thing is that it just
developed overnight.  Had no leaks before and then BAM, antifreexe pouring
all over the place.  

Just to be sure it was the freeze plug, I was able to see where the water
level dropped off to in the radiator and it seemed to be even with where
the freeze plugs on the back of the block would be located.  I wanted to
be sure before I jumped into this project.  

Well, I'm happy to say, about 12 hours later over a couple of days of
dropping the trans, exhaust, lines and cables and a few bucks for some
parts and tools, and some banged up knuckles, I was able to get to the bad
freeze plug, knock it out and put a new set in. This is not an easy job and
really not much room to work with at least for me on the garage floor but
way better then paying upwards to $1000 for a shop to do it.  Actually I
wouldn't pay that much and would have gotten another ride.

I'd recommend that you use prematex to help seal around the replacement
plugs and also pressure check the system after you put the plug in before
bolting everythin back up to make sure there are no leaks.  

So far I've got about 5 hours of driving with no leaks.  My only concern
is what will be next...  The antifreeze was rust brown and that is from
when I last changed the antifreeze about 1-1/2 to 2 years ago when the
radiator was replaced.  I'll be changing it more frequently and keeping an
eye on the cooling system overall.  At least I'm back up and running and
for only about a $10 repair...    Feeling pretty good right about now!!!  
 
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