coolant leak

[reomack]

The truck has been losing coolant at a slow but steady pace for a while. Recently it got much worse, so bad I had to do something. I couldn't find the leak and did some research which indicated that the leak might be in the heater tube that goes under the intake manifold to the rear of the engine. Only way to check is to remove the manifold. I have it off now and while the tube is rusty and will be replaced it wasn't leaking. Examining the manifold carefully I found that the passenger side rearmost mounting tab/ear is cracked and that this is also the area of the leak. The rear of the passenger side head is clean, looks like it had been steam cleaned as a matter of fact. However, looking at the manifold, the cracked ear looks like it would still clamp to the head properly as the crack is on the outside of the ear rather than being cracked in a way that would prevent pressure from being applied to the gasket. My question is am I taking too much of a chance reusing this manifold or should I buy a replacement? Any one ever have this exact problem and if so how did you resolve it?

 

[pet575]

What motor? If it is the 4.6L V8, I'd go ahead and replace the entire intake manifold. It is a known issue on the 3rd generations.

 

[reomack]

It's the 4.6 and I have decided to replace the manifold. Any problem with the Dorman? Should I get the Ford Replacement?

 

[pet575]

From personal experience, I did the Dorman and it was very easy and has help up well for nearly 100K miles. One thing you might want to do is check out the very recent threads about the cap on the passenger side blowing due to the rubber cap failing or the clamp failing. If you get the Dorman, I'd modify that cap with something better if I could do it over. Either a hi-temp plastic cap or a better rubber cap with a better clamp.

Here is my thread from when I did mine:

http://www.explorerforum.com/forums/showthread.php?t=361187

 

[Everdream]

I also have a random coolant leak on my 4.0L SOHC, looking like everything is dry, the leak itself shows in the form of my overflow bottle running low, the bottle has never been empty, but I do have to keep it up to the full line. the truck gets absolute ass for gas mileage. I have not been able to find its location yet. are these intakes also an issue on the 4.0L motor? I know about the thermostat housing, and it appears to be in good shape, with no wetness or white powder around or under it.

 

[fordysenior]

Reomack -- here's a thread where I did my intake with the Dorman, it has some helpful hints. http://www.explorerforum.com/forums/showthread.php?t=415744