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I just put a waterpump on my my E250 van. I had troubles getting one with one 5/8" and one 3/4" outlet. All the ones that I looked at had two 5/8" outlets.
The dealer doesn't carry waterpumps for a 351 as they are obsolete...and it would have been about $185...are you kdding me?
I eventually put on one from Autozone that had a rubber shim, like a piece of heater hose, that you slip over the fitting in order to increase the size to 3/4.' The ones from Oreilly, Carquest and Napa had the same shim.
If there is a next time, what should I do? Is this a common issue?
I've run across this before, but not often. I rarely if ever deal with Ford for parts. They're prices are either ridiculously cheap or at the opposite end of the pricing spectrum. If you didn't get what you wanted, ask for another waterpump. Go thru enough reman waterpumps and you'll find one with the size nipples you want. New units may have the same size nipples simply because it's cheaper for the manufacturer to stock one size nipple for the production line. You could also always pull the small nipple, tap the hole and install the size nipple you need. You can also use a short piece of 5/8 hose, then using a splice nipple to step it up to 3/4"
I tried Napa, Autozone (for multiple WPs), Oreilly and Carquest. They all had the wrong pump. IN the gasket set, there was a piece of rubber hose, to slip over the outlet and thereby shim it up. I don't know if the Napa pump had it, but the others did. The AZ pump had the best one.
An adapter wouldn't work as the bypass outlet is the wrong size and the hose is like 5" long w/2 bends in it...the longest between any bend is about 2".
The dealer lady suggested pulling the nipple and pressing in one that is the right size. I've never heard of that. But, I have heard of them leaking and having to be soldered, or brazed. I don't remember which one we did...on a '72 Pinto.
Your idea about tapping it...I like that one. That would work. I'll keep that in mind. And, I think you hit the nail on the head...the fittings are the same size in order to save .25 on each pump...on several 1,000 pumps a year, that calculates in to some real change.