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Another 02 sensor removal problem

not a port

That's not a port.
UPRTOP.JPG

If you poke a screwdriver in it you'll find that it's closed. I suspect it has something to do with molding the manifold.
 



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That's not a port.
View attachment 79615
If you poke a screwdriver in it you'll find that it's closed. I suspect it has something to do with molding the manifold.

That's an excellent pic of the intake manifold. Shows where everything goes. I'm thinking about taking mine off, but need to get a T-30 socket. Why take it off:

I lost/dropped the rear thermostat housing bolt. I know it's in the motor somewhere (not on ground). It's a real pain to get the that part of the housing, but I did, just couldn't find room to thread it back in.

Should I just forget about it, and get new bolts (plural in case I drop more)?

Are these bolts Ford only or can I get them at any auto store? I have no idea what size they are so I could just bring one into a parts store and see if they have in them? I live in the boonies and hate driving 45 minutes only to find out the auto parts store doesn't have what I need. Thoughts? Thanks!

DW
 






Upper intake manifold hose

I forgot to mention I pretty much ruined one of the air intake hoses also while pulling the thermostat housing. I was at Autozone, and the dipwit said he didn't know what exact hose/line I needed, because I didn't know what it was called. They don't have computers? Anyways I'm also looking for the name of the hose indicated in the link. It's plastic, and I'm sure it's cracked somewhere and there.

https://www.dropbox.com/s/uyoe8jbjefiyek5/intake.JPG

Thanks again!

DW
 






bad news

The bad news is that rigid plastic tube that connects the main intake tube and the IAC valve is only available new as the entire assembly from Ford and is ridiculously expensive. The flexible elbow at the IAC valve often fails. If you broke the rigid plastic section and can't find a replacement at a salvage yard then you'll have to kluge/repair yours. Possibilities are J B Weld, fiberglass cloth and epoxy resin, or cut out the broken section and replace with intake hose of the correct inside diameter. The 1997 and 1998 engines with VIS have a different assembly than the 1999 and later models: Air inlet hose fix? Don't expect the clerks at the discount auto parts stores to be an expert on your model - especially on parts they never sell because of only being available from dealers.

The screw you dropped may be on top of the transmission. I've dropped screws in that area and was able to retrieve them using a magnet on an extendable wand. I've been to several automotive fastener specialty shops trying to find an equivalent thread of those torx head screws and was unsuccessful. I think it was called a high-low thread. You'll probably have to go to the dealer for another one and may have to buy a set. I purchase my dealer only items online from Tasca Parts.
 






The bad news is that rigid plastic tube that connects the main intake tube and the IAC valve is only available new as the entire assembly from Ford and is ridiculously expensive. The flexible elbow at the IAC valve often fails. If you broke the rigid plastic section and can't find a replacement at a salvage yard then you'll have to kluge/repair yours. Possibilities are J B Weld, fiberglass cloth and epoxy resin, or cut out the broken section and replace with intake hose of the correct inside diameter. The 1997 and 1998 engines with VIS have a different assembly than the 1999 and later models: Air inlet hose fix? Don't expect the clerks at the discount auto parts stores to be an expert on your model - especially on parts they never sell because of only being available from dealers.

The screw you dropped may be on top of the transmission. I've dropped screws in that area and was able to retrieve them using a magnet on an extendable wand. I've been to several automotive fastener specialty shops trying to find an equivalent thread of those torx head screws and was unsuccessful. I think it was called a high-low thread. You'll probably have to go to the dealer for another one and may have to buy a set. I purchase my dealer only items online from Tasca Parts.

Good info. Thank you very much. I've heard of JB weld all over the net, so it may behoove me to buy some for needed repairs now and in the future.

As far as the screws/bolts for the thermostat housing, are you saying it is a special torx threading? or head? Because they come off with just a 10 (or 8?) mm socket. The only info I could find on these bolts is 10 nm 89 lb-in. I have no idea what that even means LOL.

I never fully locked down the center console, so I can remove a few screws, open up the carpet and look for the bolt I dropped.

Thanks again,

DW
 






Thermostat housing bolt

Sorry, I misread your post and thought that you had dropped one of the intake manifold screws. The thermostat housing bolts are entirely different and I purchased mine (a set of three) online from Tasca Parts. One was so corroded to the bushing in the housing that when I removed the bolt the bushing came out with it. I no longer waste time trying to find uncommon bolts locally. I just order them online.

The bolt is probably directly below the thermostat housing laying on the top of the water pump.
Remove5.jpg


Torque is measured by force times lever arm. The metric measure is newton-meters and English is pounds-feet. For small bolts feet is too large so inches are used. 1 pound-foot = 12 pound inches. I have a pound-inch torque wrench I use on small bolts/screws: 1/4 in. Drive Click Type Torque Wrench
 






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