I have read the whole topic, and while I have done some very small mechanical stuff, I am at a loss here. Last night, my 2002 Expedition sprang a leak. I couldn't really tell where the water was coming from, just dripping from somewhere on the passenger side middle right on top of the exhaust. Then i noticed right behind my water pump, is a puddle of steaming coolant. So I went back out this morning, dried it out, filled it up and restarted the truck. Puddles in the same places. Wouldn't the water come from the front if it was the water pump? And if so, what would be leaking behind the water pump? There is no water to be seen from the top, and I'm thinking its just leaking down from that spot and dripping anywhere it can find.

Thanks!

 

look at the photos on page 1.. there is a bolted on cross over pipe below the manifold that can leak due to bad o-rings or heat damage to the plastic manifold.

 

Just wanted to make sure i was in the right area atleast

 

Hello, just had my intake start leaking at crossover, 2001 233,000 miles does some one have exact part numbers need to do install with dorman and all gaskets thanks.

 

why not just go to Auto Zone or NAPA. They know the numbers, you don't need them.

 

Sorry to bump an old post but I was changing oil in my 2002 this weekend and checked the resivor, it was almost empty, I filled with a gallon of coolant and it was at the cold fill level. Drove it for the first time tonight and when i parked it and came back out it had coolant all over underneath the truck. Its leaking by the starter, poked around while it was running and found the drip on the passenger side of the crossover. its not to serious but the reseivor is low again, seems like it doesn't leak as much when its full. I'm currently away from home for about 2 more weeks so i don't have a garage to do this in otherwise I would knock it out, will it be fine driving it back home in 2 weeks, its about a 400 mile drive? I have an Edge Evolution so I can monitor the engine temp and it hasn't been overheating or getting hot.

 

I think I would be temped to put a bottle of BARS copper head and gasket sealer in the system and hope that sealed it up for a few weeks. I did that in Texas and drove back to Illinois a week later when I had the failure..... The water blowing out around the gasket will eventually get on one of the coils and cause it to short out- foul out.

 

Well turns out the intake only made it another 40 miles before it really started to leak, found the area it was leaking and knew what it was. I'm 400 miles from home so it was either pay the dealership $700+ to replace or do it myself in the driveway. Its done now, my intake was cracked at the same spot yours was so I went with a Dorman replacement since the parts store had it. Got it all put back together and it runs fine except I can hear a vacuum leak. Sounds like its coming from the PCV elbow on the back of the intake but I replaced that hose back in November when I had a lean code. Any other ideas?

 

This morning the truck threw a p1131 code. Any ideas where that leak could be coming from? I've done some research and I've read a lot about isolator bolts

 

find the vacuum leak and fix it and you have a 90% chance that the p1131 will disappear.

 

Checked it over again tonight, seems to be coming from the plastic PCV elbow that screws into the intake. Did anyone use Teflon tape or paste on those threads to help seal it? I know it's not the elbow on the pipe or the connection.

 

Everyone seems to be talking about the "plastic" U.I.M., mine is all aluminum and when I removed it I noticed pitting on the mating surface around the water openings. A new all aluminum is $500 at the dealership but the plastic ones are under $200.
Which is better? I would think the all aluminum is since it should be less likely to crack.....right?
I actually have mine in the machine shop right now having it ground and tig welded then they said they would smooth it.....for around $200. Not certain which method is best.

 

I was wondering too if there is an aluminum after market intake manifold. My '02 seems to be fine now at 103,000 miles, but now after reading this thread, I'll check real good tomorrow. Need to replace plugs, so that'll be a good time to check.

 

Actually, now ford says that aluminum part has been discontinued. You either have to repair yours or buy an after market.

 

I know this is about 2 mos old, but did you fix your vac leak? I'll bet you forgot to put that little rubber o-ring on the inatke elbow when you snapped it into the new manifold. I chased mine around for a while before I realized that is what I forgot to install..