Dorman 4.6l intake coolant leak

[Number4]

I was going to add this to another post, but there were multiple. I've added a few posts below as reference where you can find this discussed and the fixes others implemented. (I'm sure there are more which I've not included.)

This needs to be done on both the 615-175 and 615-775 Dorman replacement intakes for the 4.6l V8.

I just did this as preventative maintenance to the 615-775 intake I installed on my '03 Mountaineer.

The rubber cap that comes preinstalled is surprisingly robust, at least thick. I was expecting a thin rubber cap. The issue is that the rubber cap is not reinforced, like heater hose is.

Because the cap isn't reinforced rubber, it's closer to 5/8" ID and easily stretches. However, as noted, 5/8" heater hose will not easily fit over the plastic nipple. 3/4" heater hose fits sufficiently, though not as tight as I'd have preferred.

I was unable to locate brass fittings with a 3/4" nipple at HD and NAPA in standard brass. NAPA could order it but I wanted it "now" (NAPA 05712B-108, 3/4' Hose 1/2" Pipe.) Looking around Depot, I found the fitting I needed in the Shark Bite plumbing section. Oddly enough, the nipple in this line of product that fit the hose says it's 1". The pipe fitting portion was larger than I preferred but they had a cap to fit it.

Not the prettiest modification, but at least I can drive without the worry of losing all my antifreeze.


Note: I did this after installing the intake and had to drain quite a bit of antifreeze in order to do the repair.



http://www.explorerforum.com/forums...-615-175-intake-manifold-installation.456857/

http://www.explorerforum.com/forums...ak-on-backside-of-engine.422414/#post-3389319

http://www.explorerforum.com/forums...g-out-of-rubber-plug-on-top-of-engine.425781/

 

[mountaineer2004]

Nice and professional ! Better than most mechanics would do.

 

[Kogchris]

I was going to add this to another post, but there were multiple. I've added a few posts below as reference where you can find this discussed and the fixes others implemented. (I'm sure there are more which I've not included.)

This needs to be done on both the 615-175 and 615-775 Dorman replacement intakes for the 4.6l V8.

I just did this as preventative maintenance to the 615-775 intake I installed on my '03 Mountaineer.

The rubber cap that comes preinstalled is surprisingly robust, at least thick. I was expecting a thin rubber cap. The issue is that the rubber cap is not reinforced, like heater hose is.

Because the cap isn't reinforced rubber, it's closer to 5/8" ID and easily stretches. However, as noted, 5/8" heater hose will not easily fit over the plastic nipple. 3/4" heater hose fits sufficiently, though not as tight as I'd have preferred.

I was unable to locate brass fittings with a 3/4" nipple at HD and NAPA in standard brass. NAPA could order it but I wanted it "now" (NAPA 05712B-108, 3/4' Hose 1/2" Pipe.) Looking around Depot, I found the fitting I needed in the Shark Bite plumbing section. Oddly enough, the nipple in this line of product that fit the hose says it's 1". The pipe fitting portion was larger than I preferred but they had a cap to fit it.

Not the prettiest modification, but at least I can drive without the worry of losing all my antifreeze.


Note: I did this after installing the intake and had to drain quite a bit of antifreeze in order to do the repair.



Tips for Dorman 615-175 Intake Manifold Installation

2004 Limited w/ 4.6 Coolant Leak on backside of engine

Coolant spewing out of rubber "plug" on top of engine.

View attachment 97891

View attachment 97892

View attachment 97896

View attachment 97899

View attachment 97900

View attachment 97901

View attachment 97902

View attachment 97903

Did you put that stuff on top of the rubber cap or got rid of rubber cap completely

 

[Number4]

Did you put that stuff on top of the rubber cap or got rid of rubber cap completely

Rubber cap went in the trash.

 

[rcash]

Rubber cap went in the trash.

Did something similar to my V8 4.6l a few years ago after blowing the rubber cap off of mine. Switched to the Dorman when the OM manifold developed a leak. Fortunately I was only a few blocks from home when it happened. Has worked great since replacing.

 

[LMHmedchem]

I have not had to do this repair as of yet but I have been thinking that it might be possible to tap the inside of the port and use a threaded plug. I suppose you could also use a die and thread the outside for a cap.

Does anyone thing that such a solution would be possible?

LMHmedchem