Ford Expedition Engine Valve Cover Gasket Set Guide (2006-2017)
Address common oil leaks and burning smells by choosing the right valve cover gasket set for your Expedition's engine.
- A burning oil smell is the most common sign of a bad valve cover gasket on the Expedition.
- Oil in the spark plug wells is a definite sign the tube seals have failed, often causing misfires.
- The passenger side is harder to replace due to tight access.
- Use a quality aftermarket brand like Fel-Pro or Victor Reinz for a reliable, long-lasting repair.
Is Your Expedition Leaking Oil? It Could Be the Valve Cover Gasket.
If you're smelling burning oil or seeing drips on your driveway, a failing valve cover gasket is a likely culprit for your 2006-2017 Ford Expedition. These gaskets, made of rubber, sit in a high-heat environment and become hard and brittle over time, losing their ability to seal properly. This guide will help you understand the symptoms, choose the right aftermarket parts, and know what to expect from the repair.
Engine-Specific Issues
The 2006-2017 Expedition used several engines, most commonly the 5.4L 3V Triton V8 (until 2014) and the 3.5L EcoBoost V6 (2015-2017). While a gasket leak is a common issue on both, the 3.5L EcoBoost engines can have valve covers that crack or have integrated PCV systems that fail, requiring the entire valve cover to be replaced, not just the gasket. For the 5.4L engine, oil leaking into the spark plug wells is a very common sign of a failed gasket.
Symptoms of a Failing Valve Cover Gasket
- Burning Oil Smell: This is the most frequent complaint. Oil leaks from the gasket, drips onto the hot exhaust manifold below, and burns off, creating a distinct and unpleasant smell.
- Visible Oil Leaks: You'll see oily residue and grime collecting on the side of the engine, around the valve cover. On the 5.4L, the passenger side is a common leak point due to high heat concentration.
- Oil in Spark Plug Wells: When you pull the ignition coils to change spark plugs, finding oil in the tubes is a clear sign the spark plug tube seals (part of the gasket set) have failed. This can cause misfires.
- Low Engine Oil: A significant leak will cause your oil level to drop over time, potentially triggering the low oil light. 🎬 Watch: A quick guide to common valve cover leak symptoms.
Choosing the Right Aftermarket Gasket Set
For a part like this, aftermarket options are often as good as, or even better than, the original. The key is choosing a reputable brand. You don't need to pay dealership prices for a quality seal.
- Premium Aftermarket (Fel-Pro, Victor Reinz): These brands are well-respected in the mechanic community. Fel-Pro is often considered the top-tier aftermarket choice for gaskets and is known for its quality materials that meet or exceed OEM standards. Victor Reinz is also an excellent, often OEM-equivalent brand, known for pliable, high-quality rubber.
- Standard Aftermarket (Apex): Brands like Apex offer a more budget-friendly option. While they can be a good value, some professionals prefer to stick with the premium brands for a critical seal to avoid having to do the job twice.
Pro Tip: Check the VIN
Ford used multiple valve cover designs during this period, even within the same engine family. To ensure you get the correct gasket set, it's best to use your vehicle's VIN when ordering. This is especially important for the 3.5L EcoBoost engines.
Cost of Replacing the Engine Valve Cover Gasket Set
| Part Type | Part Cost | Shop Labor Cost | Total Estimated Cost |
|---|---|---|---|
| New Aftermarket | $48 - $101 | $220 - $322 | $268 - $423 |
| New OEM | $34 - $73 | $220 - $322 | $254 - $395 |
Cost estimates are based on national averages and may vary by location and specific vehicle model. Labor costs can be higher for 4WD models or on the passenger side, which has tighter access.
🎬 See why the passenger side valve cover is so difficult.Frequently Asked Questions
Is this a difficult DIY job?
For a home mechanic, it's moderately difficult. The driver's side is more accessible. The passenger side is tight due to A/C lines and other components, making it more time-consuming. You'll need basic hand tools, a torque wrench, and patience. Cleaning the cylinder head surface thoroughly before installing the new gasket is critical for a good seal.
🎬 Watch this step-by-step valve cover replacement walkthrough.Do I need to use RTV sealant with the new gasket?
Yes, but only in specific spots. A small dab of RTV sealant is required where the engine's front cover meets the cylinder head. The new gasket will have corners that sit on these joints. Applying sealant here prevents leaks from these critical junctions.
Should I replace anything else while I'm doing this job?
This is the perfect time to inspect and replace your spark plugs and ignition coils, especially if you found oil in the wells. On the 5.4L engine, it's also a good time to inspect the VCT solenoids, which are located in the valve covers.
Are there any recalls for this issue?
No, there are no specific recalls from the NHTSA for leaking valve cover gaskets on the 2006-2017 Ford Expedition. However, a Technical Service Bulletin (TSB 22-2200) for some 2018-2020 models with the 3.5L EcoBoost engine mentions replacing the valve cover gaskets as part of a cam phaser rattle repair, indicating the gaskets are a common part to replace during major engine service.
Helpful Videos
Technical Specifications
OEM Part Numbers: HL3Z-6584-A ML3Z-6584-G
The set includes the main valve cover gasket and spark plug tube seals. Material is typically a high-temperature molded rubber. Design varies significantly between the 5.4L V8 and 3.5L V6 engines, so verifying by VIN is critical.
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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.
- Ford Expedition:
- 🎬 Helpful Videos
- 🛍️ Shop This Part
- Is Your Expedition Leaking Oil? It Could Be the Valve Cover Gasket.
- Engine-Specific Issues
- Symptoms of a Failing Valve Cover Gasket
- Choosing the Right Aftermarket Gasket Set
- Pro Tip: Check the VIN
- Cost of Replacing the Engine Valve Cover Gasket Set
- Frequently Asked Questions
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