Ford Aerostar :: 1996 - Excessive Amount Of Steam / Smoke Coming From Exhaust


Nov 23, 2012

I've owned this vehicle since new and never overheated or had any major mechanical issues. It just hit 130,000 miles and recently completed a 1500 mile uneventful road trip running great.

The other day I noticed an excessive amount of steam/smoke coming from the exhaust while sitting at a stop light after recently starting the vehicle. Once the van was up to temperature the exhaust steam/smoke cleared up.

I checked the radiator level and found it was about a qt low, and did not seem to have any exhaust bubbling or fumes in the radiator.

Then, I pulled the dipstick and the freshly changed oil looked a bit cloudy (I got really nervous), I really can't say its milky colored because I can still see though the oil and see the cross hatches on the stick. But it doesn't look like new oil.

The engine seems to be running fine, no loss of power or missing. Starts and idles fine.

Talked with a mechanic friend and he immediately said blown head gasket or intake manifold was allowing water from one of the four corners where the gasket seals the water jacket, into a cylinder.

Since that first episode of excessive steam/smoke it hasn't reproduced the problem to that degree. It does start to steam out the exhaust after about 5 minutes of starting cold, but seems to dissipate after the engine warms.

The amount of smoke / steam in that first episode, I couldn't see the car behind me in the mirror ... I looked like a mosquito fogger.

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I noticed that after a few seconds of water spraying on my hood there was the low rolling steam coming right out of the front grill. I quickly checked all my gauges and they showed that nothing was overheating or anything like that, but I still was worried. So when the wash was over I pulled into the parking lot and popped the hood. I also noticed that steam continued for a few seconds as rolled threw the parking lot, it however stopped before I was able to get out and open the hood so I was unable to locate its source.

Upon opening the hood I found nothing that looked outta place or anything like that, abiet the engine itself was a little dusty, but that was all. Could it just have been water touching the cold manifold or something? Overall the truck hasn't been driving any differently, so that eases my mind a little.

This is cause for a little bit of concern for me, as I have never had this happen with either of the two Trucks I owned before this one. For the record my truck now has 7,000 miles on the dot on it.

Here's a Video clip of an Ecoboost F-150 ''Not My Truck'' doing the excat same thing that mine did.

2011 Ford F150 EcoBoost Looks Like Its On Fire - YouTube .....

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Yesterday afternoon I started the car after it sat for two days. A huge amount of white smoke came out of the exhaust. It ran fine. I mentioned this to my wife, she said that about two weeks ago she saw a lot of black smoke (she thinks black) when she started the car and that it ran rough for about the first 4 miles and then started running ok. It has the 2AZFE engine, and I’ve read a TSB (TSB 1507) “It has been reported that stripped head bolt threads have been found on some of these engines during tear down. When the two rear head bolts lose their clamping ability they allow coolant to seep out at the rear of the cylinder head.” Could that be the problem?

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Over time the truck warmed up and the steam stopped and everything was fine. Even when its warm outside the truck blows something when its not at operating temp but when its warm I can only see it at night when there's headlights behind me. Since I've had the truck the only thing that I've had to replace was the radiator because it was leaking coolant and even after that i still smell burning coolant occasionally and sometimes when i check my tank its low and then sometimes it never changes. Its very inconsistent.

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What could this be? something serious i hope not. i do not drive me car hard at all. its got almost 14k and changed the oil at 10k. this has never happened before. It was hot today though like 90+ ... Maybe it was just from driving it hard?

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1993 3.0 .... My son's van. He complained of fluctuating and mostly high idle, black smoke from exhaust and stalling at stoplights. He has other wheels so I've had it for several months until I could check it.

I started it every few weeks, it started easily. Have not seen smoke but it did idle high and rough. Yesterday I started it to warm it up to finally pull codes. Temp needle barely moved and upper radiator hose did not get very warm but I pulled codes with engine off anyway and got 116, 10, 111.

Today i got a little smarter and noted that the upper hose began to get warm right after startup. Suspecting a bad thermostat I blocked the radiator as well as I could and it warmed up much more, though still not near the middle of the temp gauge. Shut engine off and pulled codes again and this time got 111,10, 111.

With engine running, got 6, only-- and there's no code 6 in the code reader book. Jabbing gas pedal in neutral it nearly dies, jabbing gas in D and it dies and will not restart until cooled down.

Finally, checked again with engine off and got 111, 10, 110, 10. I think the ETC is OK since I didn't get 116 again but it still idles fast, speeds up and down erratically, and dies. Where do I go from here?

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Later the same day I checked the reservoir and it looked low so I figured the radiator sucked all the coolant up, so I refilled the resivoir tank. I spilled a nice amount when doing that, and the steam came back. It cooled down again and no more steam, figured it burnt off. The next few mornings on my first drive of the day ONLY, I saw steam. Thought it was the condensation mixing with the leftover coolant that I spilled since it didn't happen at all until the next morning.

Today was the first time it started steaming at night, and the heat stopped working again, even though the reservoir level was mostly full. I let the car cool down, and then I added more coolant and the heat started working again, no more steam either. Looked under the hood once I got home, abt a 20 min drive, resivoir was nearly empty even though car was still warm. No visible leaks on the smaller reservoir hose but there are puddles under the hood.

I've read it could be a leak of course, but also the Cap could be preventing the right pressure to suck fluid back in radiator after expanding into the surge tank, or something causing the tank to boil over....

Car is a 2013 Chevy Sonic with 68,000 miles. Coolant has never been drained/refilled since I bought the car new in 2013.

[IMG] ....

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Having an intermittent strange sound coming from the fuel pump from its normal whine at start up to a gurgling sound almost like you are blowing back through the fuel line back into the tank. Going on a 300 mile trip, should I hold off?

Btw: it's a 1996 Aerostar 3.0L

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Towed it to the mechanic and within 5-10 minutes told me it was a cracked engine, I was not there but he stated he did a compression test. Is he correct, or can it be a timing chain problem?

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What is bothering me though is that the temp gauge always seems to be right at the C, even after driving for a while. Before the van had issues, it stayed right between N and O.

Then this morning, I hear a loud pop, smell horrible burning antifreeze and smoke/steam pouring out from the hood (I managed to park it immediately, had just dropped son off at school). After I'm parked, all the antifreeze puddles underneath.

So hubby comes, and we see that the top radiator hose has blown, with a lovely crack/hole from one side to the other. Now, that hose was old, and probably was a big part of the problem.

We fixed it, and I just drove it again, but I am watching the gauge. And the van is blowing nice, HOT air from the heater. But the gauge is staying right at the C. Used to run between N and O. It is jumpy...not jumping towards hot, but little jumps...below the C, above the C, up to the N, back down to C...it just seems strange to me; it doesn't go past the N at all and spends most of its time at or below the C.

I guess I am wondering if there is any other reason why the hose could've blown this morning besides it being old and worn out....for example, excess heat and pressure building up that for some reason is not registering on the temp gauge? It's making me nervous. Is there something else besides the thermostat that could cause erratic temp gauge or cause gauge not to show me the true engine temp?

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I had a code come up a month ago which I believe was P404 but read something about EGR valve. So I replaced the EGR valve 3 weeks ago & light never came back.

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Can the lower intake manifold gasket cause the white smoke issue? This rig is also not running so great either. Rough idle, and surging, also seems to have a dead spot in the RPM range at about 3K. Oil looks and smells fine and no signs point to a head gasket other then the smoke? I swear the problem with the white smoke went away for a few days after tightening down the lower intake manifold bolts but its back again. What does everyone thing?

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