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2000 AWD Xploder from Turbo back to NA

Discussion in 'Need for Speed!' started by willzilla, June 7, 2011.

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    1. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      Me too, the PS pump is whining and my radiator has leaked barely for months. I'm not close to finishing my work truck, so I keep driving the one.

      Good luck with the fan, hopefully nothing hurt the radiator, that's a PITA.
       
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    3. willzilla

      willzilla Elite Explorer

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      Thank you. I shined flashlight up from bottom of where fan shroud/fan combo connects to radiator and nothing is touching it which makes me think something is sitting on the bottom within the shroud/fan combo piece I made that somehow fell in there and the bottom fan is bumping it. Will use air compressor/vac to see if I can figure it out without needing to pull the fan/shroud combo unit which would be a nightmare and require dumping my coolant... which I may need to do depending on the damn leak :( I could see coolant pooling a bit on the top of the engine by the heater core hoses so maybe its the valve again or the hose connections or.. something.. arg.
       
    4. willzilla

      willzilla Elite Explorer

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      I think I found the leak...

      [​IMG]

      Seems the hose clamp thingie gave up...

      Need to find some small worm clamps to swap on without needing to pull the hose... then... if that DOES fix the issue (pretty sure it does, as I tried to take rad cap off and more fluid poured out from the hose which then dripped down at the back where the leak I saw is)... I get to troubleshoot the lower fan.
       
    5. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      I forgot how tight is down in there. I hope it's not too bad, I'd want to replace those small hoses, the clamps are usually very good for decades. I have three of the coolant pipes/tubes that had no provision for the tiny outlets, just a loop from one pipe to the other. I discovered those on eBay($39.95) recently. If you have to replace that at some time, try to find the version that doesn't need the hoses; http://www.ebay.com/itm/NEW-OUT-OF-BOX-OEM-Ford-302-5-0L-V8-Explorer-Coolant-Crossover-Tube-Sensor/182422269419?ssPageName=STRK:MEBIDX:IT&_trksid=p2060353.m2749.l2649
       
    6. willzilla

      willzilla Elite Explorer

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      I tried to quiksteel weld up the cracked nipple on the tube and got everything back together and... still leaks... looks like from somewhere under the tube so it seems I will need to replace the setup or something.

      That link.. that would work? When you mention the hoses... I recall seeing a cpl pictures of the stock setup and it has 2 more small tubes that run off of it closer to the back of the truck by the heater core valve... ?

      Also... pulled my entire fan assembly (thankfully I built it so it comes out as a unit "somewhat" simply.. though A/C must be disconnected from where it bolts into the radiator... good thing I had not yet charged the system). It seems the fan itself, the plastic that the fan spins within, had warped a fraction of a centimeter and it caused the fan to brush against it a bit... So.. drilled a small hole, attached a thick zip tie.. and hooked it to the outside plastic piece pulling the plastic outward a bit and it seems to be good to go, lol.

      Thank you!!!
       
    7. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      Very good, more tweaking. That eBay link is current, I bought those a few weeks ago. Those he has don't require the tiny hoses, which most people prefer, to avoid the heating of TB etc, or a rare leak of the extra hoses. If you need one, that's about the cheapest, I got one with the pipe nipples from Ford before those, for about $55.
       
    8. willzilla

      willzilla Elite Explorer

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      Looks good to me! I don't recall seeing any tiny hoses for the TB and such, odd.

      Going to order, hopefully not to much of a pain to replace!

      Thank you!
       
    9. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      I forgot where those hoses go, they are down in there so deep. The big line fitting at the front is the toughest part, getting a wrench on it etc.
       
    10. willzilla

      willzilla Elite Explorer

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      Did you plug the tiny hoses somehow?
       
    11. willzilla

      willzilla Elite Explorer

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      The front fitting looks like it wouldn't be as bad if I pull the ignition coils out of the way... Draining the coolant is the biggest PITA for me as I have to vac fill each time, ugh. lol.
       
    12. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      My two 302 Explorer engines are still stock with the lines intact. I bought those other parts for three different vehicle projects, plus one for this 98 when I swap intake/heads etc. I'm sorry you are having to deal with that annoying leak.
       
    13. willzilla

      willzilla Elite Explorer

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      Yeah, it's a PITA, lol. Hopefully I get part Monday and can get it situated during the week.

      While waiting on the part I had installed my HID kit (https://www.xenonhids.com/dual-beam-hi-lo-9007-full-xenon-hid-conversion-kit.html?i=Kdv93R) and ran into an issue with that (not sure if I mentioned it previously).

      The ballast and relay setup worked perfectly and even fired up my old HID bulbs fine (no flicker, and both work now)... But the bi-xenon bulbs that I had received are pretty fat in the back (the mechanism that moves the bulb for low/high) and the locking ring does not slide over it to lock the bulb into place.

      [​IMG]

      So, the bi-xenon bulb would only be held into place with the rubber o-ring and just kind of sat there and that was def not going to be good enough to drive around, lol. Is there another way to "lock" the bulbs into place?

      I'd love to find some projectors with just the single bulb (9007) but all I can find are dual bulb projectors which I don't want :-/
       
    14. willzilla

      willzilla Elite Explorer

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      May order 2 more... cut them and then fit around base of bulb and epoxy back in place and then turn them to lock bulbs in place... lol.
       

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    15. willzilla

      willzilla Elite Explorer

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      Wow... Fast shipping. Got my part in today!

      [​IMG]

      Now to figure what I do with the two hoses that plug into the old pipes lol. There is some kind of U pipe on the replacement part.

      Can I just tie the 2 hoses into each other or something?
       
    16. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      Yes, just run one hose in place of the two, to where they come from. That was fast shipping, some sellers are on the ball, good.
       
    17. willzilla

      willzilla Elite Explorer

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      So.. just loop them together ... Awesome. What are the hoses original purpose?
       
    18. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      I'll have to look, it's almost always about heating the TB area.
       
    19. willzilla

      willzilla Elite Explorer

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      Interesting .. would be simple if that's all it's for ! Lol.
       
    20. willzilla

      willzilla Elite Explorer

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      A bit confused...

      I tore out most of everything in the way of the intake manifold heater inlet tube. I'm at the point of removing the big connector section of the tube...

      [​IMG]

      The bolt turns but... Do I continue loosening the bolt or, looking at the connector...

      [​IMG]

      Do I just pop out the connector up and out or do I loosen the bolt completely and then the connector comes out?

      Thanks!
       
    21. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      Hopefully someone else will pop in and say how hard you have to pull on it. I've not had to pull one of those off an Explorer engine yet. The fitting going into the intake is the same thread type for any SBF, but that o-ringed part is a new design. I saw that too when I got the coolant pipes, I figured seeing the old part would make it obvious when it's out.

      I think it will be easier to remove it with the intake fitting in place. It'd be harder to separate the fitting if it's not in the intake, out in hand with the coolant pipe. Let's ask Jon(Turdle) or any of our regular 302 guys, they'll all know.
       
    22. willzilla

      willzilla Elite Explorer

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      Ok, thank you for the info. Couldn't find any info in the shop manual on the procedure.

      So.. Leave the bolt screwed in and just "pry" the fitting up and out from the engine and big nut?

      Thanks!
       
    23. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      I think so, I think it's like the fuel injectors, a good seal with a simple bracket and bolts to hold it down.
       
    24. willzilla

      willzilla Elite Explorer

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      Thank you! I'll try that tomorrow after work... And re-tighten the bolt back in place as I loosened it a bit before deciding to think a bit on it lol.
       
    25. willzilla

      willzilla Elite Explorer

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      Got some work done today.

      I ended up prying off the inlet tubes which of course snapped where it connected into the big bolt piece.

      [​IMG]

      [​IMG]

      I then was able to get a ratchet on the bolt (it's a 1") and was able to remove it pretty easily at that point and then punched out the tip that was still stuck within the bolt. I then cleaned the bolt up and re-installed it into the engine.

      [​IMG]

      [​IMG]

      Once installed I then installed the new inlet tube and also cut one of the 2 hoses that had went from the intake to one of the old intake tube nipples and then yanked the second hose completely off from the inlet and then U'd the one hose into the other hoses old inlet spot so the one hose goes from the intake back to the intake to keep it blocked off.

      [​IMG]

      Re-connected and re-install everything and pulled vac on the coolant system and... not holding. A leak somewhere, ugh. Seems the waterpump bolts loosened again or something. Started to rain and get dark and had to take kids out for Halloween so will delve into it further tomorrow.

      Once potential issue is the waterpump bottom outlet port I "believe" is 1 1/2" but the radiator hose is 1-1/2" to 1-3/4" with the 1-1/2" plugged into the 1-1/2" radiator port and the 1-3/4" is on the 1-1/2" waterpump port which I had used some red gasket stuff and torqued crap out of the screw clamp but that is probably not a great solution (though I couldn't hear any leaking air from that area).

      May try to replace hose with a 1-1/2" to 1-1/2" flex hose or something.
       
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    26. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      That looks good, and those are great pictures. For the possible leak, check the outlet/nipples of the water pump. If they are a casting, sometimes the edge isn't smooth and the hose there won't weal it completely.

      I had that happen with my 99, a NAPA WP had a poor inlet side casting, and it leaked a lot at that hose connection. I had to grind down that surface, with it in the truck, my SOHC engine.
       

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