Has anyone seen a Zetec headgasket leak to the outside of the engine, and down the block (I see nothing on the search)? After 2 waterpumps's, the repair shop is now telling me that it's been the headgasket all along.

Never seen that, but anything is possible.

Should be fairly easy to check though, huh?

I've been wondering the same thing on my car? Where on your block is it leaking? Air intake side? That is the side mine is leaking from. I plan to tackle this more this weekend. I have already gone through an upper Rad hose. The heater return hose below that rad hose. Then I did the thermostat housing. Disovered there was definatley a leak there at some point. I had put stop leak in a while a ago and you could see where it had been working. Today I took the heat sheild off to get a better view for tomorrow. I also hosed all the coolant and dye off the engine bay. There has been fluid pooling on the transmission case. The dealership says it may be the head gasket leaking outside the block since it seems to be nothing else. I'm still trying to get all options exhausted before I drop serious coin doing the HG.

Mine is leaking under the timing cover, near the WP. The shop quoted a price of $11XX.00 to change it. Yea right, the cars hardly worth that, so I am going to try this new sodium silicate based block sealer called K&W Block Sealer.

I have google'ed a lot of positive results on it. It is supposed to be the best thing going. The silicate turns to a glass and seals like nothng else according to what I've read. It talks about the hot exhaust gases burning the silicate and turning it to glass, so I am not 100% sure it will work on an external leak. I figure it's worth $6 to try it first though. What can it hurt?

Here a a couple links to info:
http://www.allpar.com/fix/cracks.html
http://www.carshowtomt.com/tc/Welcome.html?article=Squeaky__Rusty_Brakes_and_Engine_Woes

Well i just read the link and though it sounds like a great product it seems to really on high heat to seal. I.E. the firing of a cylinder. I'm not so sure it would do anything for our external leaks.

Actually, I called the company's 800 line and they said it will work on any leak.

I put it in last night, and it is 'curing' for 24 hrs. I am going to put it back together tonight. I will post the results when I have them.

Holy Cow, it's holding. I drove about an hour and a half. Not a single drip. The real question, is this permanent as touted by the product. Only time will tell, but certainly worth the $6 to try it out.

I'll try to remember to post results in a few weeks.

One week and about 500 miles later, no leaks. I'd call this stuff the $6 miracle in a can!!!

Still Holding!!! Just updating for 'searches'.