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4.2 intake water leak at heater hose

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Old 01-22-2011, 03:37 PM
sleepinghound sleepinghound is offline
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Question 4.2 intake water leak at heater hose

I have a 1999 f-150 2wd w/4.2. On the front of the intake manifold there is a metal tube molded/pressed into intake. This tube has a hole in it and is leaking. Is there a fix for this or does entire manifold need to be replaced? I used JB weld on it and it worked for a while but then it softened and started to leak again. Any help would be appreciated. Thanks
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Old 01-22-2011, 03:42 PM
99RatFinkFord99 99RatFinkFord99 is offline
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this happend alot in the 1997-1999 4.2l's after about 100k the manifold would leak into the top end...i think i heard that ford had a callback on that but im not sure, but the best thing to do in this case is to replace the manifold...
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Old 01-22-2011, 09:24 PM
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moto57 moto57 is offline
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Old 07-16-2011, 04:49 PM
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mrv8outboard mrv8outboard is offline
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I realize this is an old thread but I would like to update it as I just repaired a lower intake bypass pipe.

1st I first removed the old pipe and the piece left in the intake.

2nd Was to drill the hole with a 13/16" drill bit and chambered the leading edge with a 7/8" drill bit.(This was to make the lead in for the tap).

3rd Tap the hole with a 1/2" pipe tap. (I used 95% of the taps depth).

4th Assembled a 1 1/2"x1/2"NPT nipple into a 90* fitting and out of that with a 1/2"NPT x 3/4" barbed nipple.

5th Installed this assembly and the intake was fixed. (Now came the rest of the upper intake assembly).
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Old 04-03-2012, 07:14 AM
renchr56 renchr56 is offline
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update to this old thread

I found a replacement Ford OE part.. # F75Z-8555-AB. This is the exact part to the one that continually rusts out.
First I cut off the old tubeflush. then I took a small ( and I mean small ) hacksaw and cut throught the remaining piece that is still in the manifold. I then could get the piece out. I then coated the new piece with gasket shellac and made a homemade driver out of 1/2" pipe by cutting one side off. I used it to drive the new pipe home. Works great and no leaks.
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