97 XLT 4.0 SOHC - Coolant drip on passenger-side, front of engine

[2TimingTom]

Yes sir

I should also add that it only leaks while revving. I can open the throttle plate by hand and see it stream out- can't pinpoint a source, but it is above the water pump for sure.

 

[donalds]

If it is leaking then I assume the system is not pressurized
Therefore if you rev it up the pump spins faster therefore lowering the atmosphere ..pressure... in the cooling system sucking in more fluid in from the over flow tank then you let off the gas an the engine returns to idle the water pump spins slower therefore a rise in pressure in the system
Pressure causing the coolant to leak out of the crack
Or at least that's how I see it

 

[2TimingTom]

I ordered the Simmons Autosports all aluminum housing.

I pulled out the plastic housing and I didn't see any obvious signs of it leaking. But sometimes it takes pressure to open up those small cracks.

 

[donalds]

Cool beans

 

[ctgriffi]

I finally ordered all the parts and got this job going. Removal of the thermostat housing was worse than I expected. Seems like all the how-to videos out there show models or years that don't have wires/pipes/hoses covering everything.

Anyway finally got it removed (didn't break any tabs off in the process!). The housing isn't in terrible shape, but obviously had a growing crack on the bottom side. Glad to get this replaced and seal up that leak.

Anybody have advice about installing the new sensors into the new housing with these Dorman 800-019 clips? Just doing a test-fit, I cannot get the clips to insert fully, pop into place, etc. They seem oversized or something. What am I missing?

 

[swshawaii]

Each "leg" of the horseshoe clip goes in a slot. Make sure the sensors are seated in each port, and the clips are pushed all the way in. Some aftermarket sensors have been reported oversized and don't fit properly. Also got a good tip from another EF thread to tie string, fishing line, or even dental floss to the clip in case it flies off. Would be very difficult to find in the engine bay or on the ground. Linked pic shows the clip partially inserted. Hope this PhotoBucket link works.

Photo by swshawaii

 

[ctgriffi]

Understand now, thanks for the info and photo, swshawaii. I thought the clip was just "halfway" inserted at that point, but guess that's all we need. Appreciate it!

(File attached, in case that FB link goes down...)

 

[RandomNerd2000]

I should at some point, being someone who can edit videos for YouTube at least halfway there, make a video showcasing this replacement since I've done it multiple times.

 

[XLTrunner]

Perhaps we could co-produce a How -To video! I could probably remove the upper intake and t-stat housing blindfolded I've done it so many times...lol

 

[RandomNerd2000]

I've done it enough times I could, minus tools, do it in 45 minutes from swapping housings to coolant filling. I had a bad headgasket and it made them bust pretty often.

 

[ctgriffi]

Finally got that thing all finished up last night and tested. No leaks so far, although I'll need to monitor for awhile. I did it without pulling the upper intake off, which made things very difficult, and probably didn't shave any time off the job. Managed to not break any tabs off either on the new Motorcraft RH144 housing—that plastic ain't metal, for sure, but it is pretty tough stuff, regardless...

My issue with the Dorman clips was this: I've worked on a lot of cars but have never come across those kind of push-in sensors. Initially, I thought that the clip needed to go in one slot, around and past the sensor, and out the other side! Much easier the right way, keeping the clip on the outside, haha.

Thanks again guys, especially XLTrunner and swshawaii, for the links, part numbers, and general assistance. Much appreciated!

 

[donalds]

Awww... sorry man when that one starts to leak just ask for a link to the metal housing

 

[ctgriffi]

Awww... sorry man when that one starts to leak just ask for a link to the metal housing

Ha, I'll keep that in mind.

To me, it's a 21 year-old, hand-me-down Ford with a ton of miles. Fun in the snow and good for hauling the odd load of firewood, but it ain't a collectible. I'll happily drop it at the junk yard before I start ordering custom-aluminum-anythings for it...

 

[donalds]

Ya don't know what you got until it's gone
That said I love these trucks
My truck won't see a junk yard any time soon I think it's because I take care of it and a CHEAP aluminium housing is the best way to fix it in this sort of situation
Whether if it's a junkyard worthy truck like you say yours is
Or a nicer truck like I think I have
Still the best logical way to go is a permanent repair
And SOME people do kinda collect them

 

[RandomNerd2000]

You'll find otherwise, I drive a $200 V8, and am building a V8 Eddie Bauer, both trucks I said "I won't attach to, or spend too much in"...Meanwhile I just spent $400 for a parts truck for the $200 one, and am V8 swapping the Eddie Bauer which hasn't been cheap yet. As for collectors? That's me if there is such a thing, I love the 2nd gens.