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My dictionary says hose A quick fix is to the cut the brittle rubber end and hope there's enough slack to reconnect the hose. The 16 year old plastic connector might be failing as well or will disintegrate when you touch it. I don't have a parts diagram but the plastic connector is probably something in this list - https://www.fordpartsgiant.com/parts...ter_hoses.html - or this list - https://shop.advanceautoparts.com/fi...-hose-fittings . Depending on what you find, consider replacing the connector with a brass fitting for longevity.
The picture isn't clear to me - is the spring clamp directly over rubber hose or is it over the spiral loom as well?
Upon close inspection, the coolant seems to be cascading down from somewhere above. I don’t want to jump to conclusions again but this looks like a more extensive job.
I had it parked for a couple days and now I can see there’s a steady drip. I can’t yet identify where. Doesn’t look good
You can rent a cooling system pressure tester net for free from most auto parts stores. Pressurize the system to 15psi then look for the source of the leak. If pressure drops rapidly, have a second person try to maintain 15psi while you look in the doghouse area.
^Yes. I think you are right. I can see coolant pooling on top of the engine block beneath the intake manifold on that driver’s side, as well.
I borrowed a pressure tester from Autozone. It wouldn’t hold any pressure when I pumped it up. Maybe the leak is too big?? I think I had it hooked up right. I guess the test just confirmed what I can see now.
Most importantly, the leak is definitely flowing very conspicuously from that area. I don’t see any other leaks currently.
Any other tests/troubleshooting to take care of. before I go ahead and start the process of removing the intake manifold?
There isn't much you can do until you solve the large leak. I would definitely pressure test after you do the job in case it springs a leak elsewhere though.
I pulled the intake manifold today. I can’t tell if the leak is from a gasket or the intake itself. How can I tell?
In any case, I think I’ll replace the intake manifold. It may be the original. It hasn’t been changed in my ownership (~150k) and there’s 250k miles total. What else could I change/clean at this point?
^Yes. I think you are right. I can see coolant pooling on top of the engine block beneath the intake manifold on that driver’s side, as well.
I borrowed a pressure tester from Autozone. It wouldn’t hold any pressure when I pumped it up. Maybe the leak is too big?? I think I had it hooked up right. I guess the test just confirmed what I can see now.
Most importantly, the leak is definitely flowing very conspicuously from that area. I don’t see any other leaks currently.
Any other tests/troubleshooting to take care of. before I go ahead and start the process of removing the intake manifold?
It has to be "full of coolant" to use a pressure tester.
Fill the radiator completely up a couple of times over a 10 minute time frame and retest with the pressure tester, is how it's done
I pulled the intake manifold today. I can’t tell if the leak is from a gasket or the intake itself. How can I tell?
In any case, I think I’ll replace the intake manifold. It may be the original. It hasn’t been changed in my ownership (~150k) and there’s 250k miles total. What else could I change/clean at this point?
Inspect the underside of the plastic intake where the aluminum thermostat housing meets the plastic
See if the O-ring grooves are cracked. That is the leak usually on a 5.4 or 4.6 with that style of intake
See how the ledges are broken / worn down /cracked on the intake where the cooling port O-rings go?
Pull those O-rings out and take a closer look
Looks like to me you will need to replace the intake manifold to fix the coolant leak
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A quick fix is to the cut the brittle rubber end and hope there's enough slack to reconnect the hose. The 16 year old plastic connector might be failing as well or will disintegrate when you touch it. I don't have a parts diagram but the plastic connector is probably something in this list - https://www.fordpartsgiant.com/parts...ter_hoses.html - or this list - https://shop.advanceautoparts.com/fi...-hose-fittings . Depending on what you find, consider replacing the connector with a brass fitting for longevity.
