There is a 1/2" dia. tube that is on the left side of the alternator that has a 1/4" tube that branches off of it about 2" back from the end of the 1/2" tube. The 1/4" section broke off of the 1/2" tube and water began leaking everywhere. I don't know what this tube is called but it goes up to the throttlebody area carrying coolant. Can I remove this tube without removing the intake manifold? The parts guy at the Ford dealership said the intake has to come off. I'm hoping I can just remove the fan shroud, fan and alternator and avoid a top end tear down. Has anyone had to replace this tube?

 

Would this be a 4-valve motor?

 

It's 2000 5.4 liter V8. I don't know if the 5.4 was cam in block in 2000 or overhead cam with multiple valves per cylinder. The tube curves around in a "U" shape behind the alternator so you can see the other end of the tube(end that didn't break).

 

The only coolant tube on my 98 runs underneath the manifold to the back of the water pump. Maybe Ford redesigned the coolant return on later models. It may have a path that does run in the valley. If so, then you'll have to pull the manifold.

 

The alternator is still in place so I can't see the "U" portion of the tube, but I can see both ends. The end to the left of the alternator is fully exposed(this is where the 1/2" and 1/4" hoses connect and the other end goes into the back of what I'm guessing is the water pump. The strange thing is the side that goes into the water pump has a flared end which would make you think it should have a threaded nut on it to screw into the water pump, but it doesn't. I'm curious as to how it is fastened to the water pump because of the flared end. There is some room between the bottom of the intake manifold and the top of the lifter valley so that's why I'm asking if the room is sufficient to get this tube out without removing the intake. That would save a whole lot of time. If the intake has to come off the plugs will be changed as will any rubber components in the neighborhood. There are no misfire DTC currently so I guess the COPs are OK for now. The owner is a little strapped for cash so I know with labor and parts he's going to say "OUCH" if the manifold has to come off. Oh, well it's only money. His money.

 

On the 98, the tube that runs into the back of the water pump underneath the manifold bolts to the back of the right cylinder head and is supplied by a T in one of the heater hoses. This tube is about 3/8 or 1/2 OD and is pressed into a flared tube in the back of the water pump. Can you use a mirror and light to see the back of the water pump? If this tube or the 2000 version of it has come loose, there's no reason you can't rerout the tube outside of the valley then back down to the pump.

 

I'm hoping once I get the alternator out I'll be able to see the other end of this tube much better. As it is currently I can just barely see where it terminates. I'll get this truck Fri morn. and will post my results. I'm hoping the parts clerk was wrong when he said the intake has to come off. Sometimes the parts clerks are right about these things, but many times they are way off base and I hope this is one of those times. If I have to remove the intake I'm going to strongly suggest new plugs and some EGR preventative maintenance be done as well.

 

Any update?

 

The customer wants to wait until Friday(payday to do the work) so I'll update Fri afternoon or Sat morn.

 

Any updates

 

Well, 13 years later I doubt we'll get an update....

 

Had to take the alternator off to get to it. It has one bolt next to the alternator that holds it on. It wraps around like ‘U’ and connects to the back of the water pump.