Engine Valve Cover Gasket Set Guide for 1991-1995 Ford Explorer
Leaking oil and smelling burning? It's a common issue on first-generation Explorers, and this guide will help you choose the right gasket to fix it.
- Valve cover gasket leaks on the 1991-1995 Explorer are very common due to the age and material of the original gaskets.
- The job requires removing the upper intake manifold, so you should replace the intake gaskets at the same time.
- Choose a quality aftermarket brand like Victor Gaskets for a more durable, modern rubber seal.
- Always replace the rubber bolt grommets with the gaskets to ensure a proper seal.
Is Your Explorer's Valve Cover Gasket Failing?
If you own a first-generation Ford Explorer with the 4.0L OHV V6 engine, chances are you'll deal with a valve cover gasket leak at some point. The original gaskets, often made of cork or early rubber composites, become hard and brittle from years of heat cycles. This causes them to shrink and crack, breaking the seal and allowing oil to seep out.
This is a very common repair. The good news is that modern aftermarket gaskets often use superior materials compared to the originals, offering a more durable and long-lasting seal.
OEM vs. Aftermarket Gaskets
For a vehicle of this age, original equipment (OEM) gaskets from Ford may be difficult to find or expensive. Aftermarket brands are the most practical and popular choice. High-quality aftermarket gaskets from brands like Victor Gaskets often use modern rubber compounds that are more resistant to oil, heat, and becoming brittle. These can provide a better, longer-lasting seal than the original factory parts. Budget-friendly brands like Apex also provide a functional seal that meets basic requirements, making them a viable option for cost-conscious repairs.
Pro Tip: Replacing the valve cover gaskets on the 4.0L OHV engine requires removing the upper intake manifold. Because of this, it is highly recommended to replace the intake manifold gaskets at the same time to avoid future leaks and save on redundant labor.
Choosing the Right Aftermarket Brand
When shopping for a new valve cover gasket set, you'll find several options. Here’s a breakdown of the available brands:
- Victor Gaskets (Victor Reinz): Often considered a higher-tier aftermarket brand, Victor Reinz is known for producing gaskets that meet or exceed OEM quality. They are often made from pliable, high-quality rubber that provides an excellent seal, even on older engines with minor imperfections on the sealing surfaces. Many professional mechanics trust this brand for its reliability.
- Apex: Apex is a budget-friendly aftermarket brand. While generally considered a more basic option, their gaskets are functional and can perform well if the engine surfaces are clean and properly prepared. For an older vehicle or a DIY mechanic on a tight budget, Apex can be a suitable choice.
| Item | Estimated Cost |
|---|---|
| New Aftermarket Gasket Set | $31.94 - $65.95 |
| Shop Labor | $140 - $656 |
| Total Professional Replacement | $203 - $735 |
Known Issues & Recalls
There are no specific NHTSA recalls or Technical Service Bulletins (TSBs) for the valve cover gaskets on the 1991-1995 Ford Explorer. However, TSB 95-9-10 was issued for a related part, the intake manifold gasket, due to coolant leaks. Since the intake manifold must be removed to access the valve covers, it's wise to address both gasket sets at the same time.
Frequently Asked Questions (FAQ)
What are the most common signs of a bad valve cover gasket?
The most common signs are visible oil 🎬 Watch this video to identify symptoms of a bad gasket. leaking from the top of the engine, a burning oil smell from oil dripping onto the hot exhaust manifold, low engine oil levels, and, in some cases, engine misfires if oil leaks into the spark plug wells.
🎬 Learn more about the top signs your gasket needs replacement.Is this a difficult job to do myself?
For the 4.0L OHV engine, the job is moderately difficult due to the need to remove the upper intake manifold to access the passenger-side valve cover. While it can be done by a skilled DIY mechanic with the right tools, it is more involved than on many other engines. It requires careful disassembly of components on top of the engine.
Should I use sealant on the new gaskets?
Generally, modern rubber gaskets are designed to be installed dry. However, a small dab of RTV sealant is often recommended at sharp corners or where the timing cover meets the cylinder head to prevent small leaks in these critical areas. Always follow the specific instructions included with your gasket set.
Do I need to replace the bolts or grommets?
Yes, it is highly recommended. Many gasket sets include new bolt grommets. These rubber grommets harden and crack just like the gaskets, and old ones can prevent the valve cover from being torqued down correctly, leading to a poor seal.
Helpful Videos
Technical Specifications
Fits 4.0L OHV V6 Engine. Set typically includes two valve cover gaskets and bolt grommets.
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The information in this article is provided for general reference and educational purposes only. Vehicle specifications, procedures, and part compatibility can vary by production date, trim level, and region. Always consult your vehicle's factory service manual and verify part numbers before purchasing or performing repairs. Safety-critical components such as airbags, seat belts, and braking systems should be installed by a qualified professional.
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