Coolant System By-Pass Kit
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Senior User
Joined: Mar 2003
Posts: 366
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From: Aloha (Portland), OR USA
Coolant System By-Pass Kit
Hey Everyone,
I posted a message about six months ago about a cooling system problem with my '93 3.0 AT 2WD Ranger. Basically, when it warms up I get a loud knocking noise from the thermostat housing area. It seems like there is air trapped in the cooling system, but no matter what I have tried to do to get it out, I still have the same problem.
I talked with a shop last week about this problem, and one of the mechanics working there is an ex-Ford tech, and he said there was a TSB out about this issue. It is TSB 96-21-12, and it describes the exact problem I am having. Apparently to fix it, you have to install a cooling system by-pass kit (p/n F47Z-8522-F), which includes a coolant by-pass kit, replacement lower radiator hose, and elbow-hot water heater connection. It lists for almost $200, and I can probably get it online for about $150.
Before I spend the money, I was wondering if anyone else has experienced this same problem and if the kit solved it. Also, I am trying to figure out exactly what this kit does to see if I can replicate if for cheaper.
Thanks in advance!
I posted a message about six months ago about a cooling system problem with my '93 3.0 AT 2WD Ranger. Basically, when it warms up I get a loud knocking noise from the thermostat housing area. It seems like there is air trapped in the cooling system, but no matter what I have tried to do to get it out, I still have the same problem.
I talked with a shop last week about this problem, and one of the mechanics working there is an ex-Ford tech, and he said there was a TSB out about this issue. It is TSB 96-21-12, and it describes the exact problem I am having. Apparently to fix it, you have to install a cooling system by-pass kit (p/n F47Z-8522-F), which includes a coolant by-pass kit, replacement lower radiator hose, and elbow-hot water heater connection. It lists for almost $200, and I can probably get it online for about $150.
Before I spend the money, I was wondering if anyone else has experienced this same problem and if the kit solved it. Also, I am trying to figure out exactly what this kit does to see if I can replicate if for cheaper.
Thanks in advance!
Post Fiend
Joined: Jan 2003
Posts: 9,748
Likes: 16
From: Connecticut
3.0L Cooling System Thump - Temperature Gauge Fluctuation
I don’t have any personal experience with the kit, but FWIW there is a similar type of kit for the 4.0L which addresses the same concern (steam formation in cooling system).
Here is the full TSB covering the 3.0L referenced by the shop:
Here is the full TSB covering the 3.0L referenced by the shop:
Article No. 96-21-12
LIGHT TRUCK: 1991-95 RANGER 1995 AEROSTAR
This TSB is being republished in its entirety to include the 1995 model year and to add Aerostar to the list of affected vehicles.
ISSUE:
A "knocking/thumping" noise may be audible in the passenger compartment on some vehicles. This noise is most pronounced with the engine at normal operating temperature. The noise is caused by steam formation in the cooling system. The noise is then transmitted through the heater hoses and heater core.
ACTION:
Install a Coolant By-Pass Kit. This increases coolant flow which reduces steam formation. Refer to the following Diagnostic and Service Procedure for details.
DIAGNOSTIC AND SERVICE PROCEDURE
1. Check that base timing is at 10* BTDC with SPOUT disconnected.
2. Check for excessive exhaust system restrictions. A restricted exhaust could elevate cooling system temperatures.
3. If dash-mounted cooling temperature gauge fluctuates, check that gauge and sending unit are functioning properly.
4. Check for restrictions or kinks in the radiator or heater hoses.
5. Pressure check cooling system for leaks.
6. Confirm proper Engine Coolant Temperature (ECT) sensor signal to EEC-IV processor. Refer to TSB Article 93-24-8 (Cooling System - Thermostat Diagnosis) for tool and procedure to check thermostat.
7. Check for correct 50/50 coolant mix. Verify that freezing point is -37̊C (±-3*C) or -35*F (±5*F).
8. For 1991-93 Rangers, install a 110 kPa (16 psi) Radiator Cap (F4TZ-8100-B). NOTE: These model year vehicles originally came with a 90 kPa (13 psi) radiator cap.
9. If concern still exists, install service Coolant By-Pass Kit and verify that concern has been resolved. Refer to the Application Chart:
PART NUMBER / PART NAME
F57Z-8522-AA / By-Pass Kit (1995 Ranger)
F59Z-8522-CA / By-Pass Kit (1995 Aerostar)
F47Z-8522-A / By-Pass Kit (1991 Ranger With Automatic Transmission)
F47Z-8522-B / By-Pass Kit (1991 Ranger With Manual Transmission)
F47Z-8522-C / By-Pass Kit (1992 Ranger With Automatic Transmission)
F47Z-8522-D / By-Pass Kit (1992 Ranger With Manual Transmission)
F47Z-8522-E / By-Pass Kit (1993-94 Ranger With Automatic Transmission)
F47Z-8522-F / By-Pass Kit (1993-94 Ranger With Manual Transmission)
F4TZ-8100-B / Radiator Cap
OTHER APPLICABLE ARTICLES:
93-24-8
SUPERSEDES:
95-12-8
LIGHT TRUCK: 1991-95 RANGER 1995 AEROSTAR
This TSB is being republished in its entirety to include the 1995 model year and to add Aerostar to the list of affected vehicles.
ISSUE:
A "knocking/thumping" noise may be audible in the passenger compartment on some vehicles. This noise is most pronounced with the engine at normal operating temperature. The noise is caused by steam formation in the cooling system. The noise is then transmitted through the heater hoses and heater core.
ACTION:
Install a Coolant By-Pass Kit. This increases coolant flow which reduces steam formation. Refer to the following Diagnostic and Service Procedure for details.
DIAGNOSTIC AND SERVICE PROCEDURE
1. Check that base timing is at 10* BTDC with SPOUT disconnected.
2. Check for excessive exhaust system restrictions. A restricted exhaust could elevate cooling system temperatures.
3. If dash-mounted cooling temperature gauge fluctuates, check that gauge and sending unit are functioning properly.
4. Check for restrictions or kinks in the radiator or heater hoses.
5. Pressure check cooling system for leaks.
6. Confirm proper Engine Coolant Temperature (ECT) sensor signal to EEC-IV processor. Refer to TSB Article 93-24-8 (Cooling System - Thermostat Diagnosis) for tool and procedure to check thermostat.
7. Check for correct 50/50 coolant mix. Verify that freezing point is -37̊C (±-3*C) or -35*F (±5*F).
8. For 1991-93 Rangers, install a 110 kPa (16 psi) Radiator Cap (F4TZ-8100-B). NOTE: These model year vehicles originally came with a 90 kPa (13 psi) radiator cap.
9. If concern still exists, install service Coolant By-Pass Kit and verify that concern has been resolved. Refer to the Application Chart:
PART NUMBER / PART NAME
F57Z-8522-AA / By-Pass Kit (1995 Ranger)
F59Z-8522-CA / By-Pass Kit (1995 Aerostar)
F47Z-8522-A / By-Pass Kit (1991 Ranger With Automatic Transmission)
F47Z-8522-B / By-Pass Kit (1991 Ranger With Manual Transmission)
F47Z-8522-C / By-Pass Kit (1992 Ranger With Automatic Transmission)
F47Z-8522-D / By-Pass Kit (1992 Ranger With Manual Transmission)
F47Z-8522-E / By-Pass Kit (1993-94 Ranger With Automatic Transmission)
F47Z-8522-F / By-Pass Kit (1993-94 Ranger With Manual Transmission)
F4TZ-8100-B / Radiator Cap
OTHER APPLICABLE ARTICLES:
93-24-8
SUPERSEDES:
95-12-8
Thread Starter
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Senior User
Joined: Mar 2003
Posts: 366
Likes: 0
From: Aloha (Portland), OR USA
Thanks for the response Rockledge!
I will probably just bite the bullet, order the kit, and hope it fixes the problem. The TSB describes my exact problem, so I'd think the kit will fix it.
I notice you have a 94 SHO MTX - how do you like it? I've had my 95 MTX for five years now and love it. Even with 120K on the clock, it runs like new and will still beat a majority of the cars on the road.
I will probably just bite the bullet, order the kit, and hope it fixes the problem. The TSB describes my exact problem, so I'd think the kit will fix it.
I notice you have a 94 SHO MTX - how do you like it? I've had my 95 MTX for five years now and love it. Even with 120K on the clock, it runs like new and will still beat a majority of the cars on the road.
Post Fiend
Joined: Jan 2003
Posts: 9,748
Likes: 16
From: Connecticut
I've had my SHO less than 2 years, picked it up cheap and have whipped it into good shape (145K). Currently it's running tip top. I don't drive it much in the winter but I took it for a rip just last weekend and boy did it feel good. 
As a matter of fact I was recently tooting my SHO's horn in this thread:
https://www.ford-trucks.com/forums/s...d.php?t=330601
I checked out yours, it looks like it's in great shape, and your description of the SHO along side the pics is a nice touch, especially for those people who aren't that familiar with it.
Good luck with the by-pass kit, keep us posted on the results.
As a matter of fact I was recently tooting my SHO's horn in this thread:
https://www.ford-trucks.com/forums/s...d.php?t=330601
I checked out yours, it looks like it's in great shape, and your description of the SHO along side the pics is a nice touch, especially for those people who aren't that familiar with it.
Good luck with the by-pass kit, keep us posted on the results.
New User
Joined: Dec 2013
Posts: 3
Likes: 0
Thumping from cooling system
91 ranger v6, 4.0L, had the same problem for years. new hoses, new thermostat did not solve the problem. temp gauge works fine. just saw this posting a few days ago. tried item #8 on the above TSB: replaced 13lb cap with 16lb cap (ford motorcraft RS-90). The cap switch did dampen the thumping sound somewhat but I still have the problem. Don't want to spend $240 to buy the coolant by-pass kit. And besides, I have lived with "Thumper" for 20 years--he is like an old friend who lives in my glovebox.
Thanks for posting the bulletin!
Thanks for posting the bulletin!
3rd Gear
Joined: Feb 2014
Posts: 3
Likes: 0
Coolant Pulse
OK people, so now that I have the pulse problem, where can I get A water pump by-pass kit. I'm told by Ford, that the PN#F47Z-8522-E is no longer available. Auto Parts stores have no idea about the kit.Please Help. Jon Ford
New User
Joined: Dec 2013
Posts: 3
Likes: 0
Coolant system recovery kit
This place had one 3 months ago. Dunno if they still do.
Bob Allen Ford Parts
9239 Metcalf Ave
Overland Park, Ks. 66212
Cell # 913-707-0054
Parts # 913-381-2999
Fax # 913-383-2947
Wanted $292 plus shipping
Part #: F47Z-8522-A
Obviously, please verify all this stuff, don't take my humble word for it.
Bob Allen Ford Parts
9239 Metcalf Ave
Overland Park, Ks. 66212
Cell # 913-707-0054
Parts # 913-381-2999
Fax # 913-383-2947
Wanted $292 plus shipping
Part #: F47Z-8522-A
Obviously, please verify all this stuff, don't take my humble word for it.
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Cargo Master
Joined: Feb 2002
Posts: 2,414
Likes: 22
From: Tucson USA
go to NAPA, they have the head and filters for the coolant system to install. Not very hard to do this is something that is discussed on the diesel sites often. They can be purchased from some diesel dealers for AM parts. I made my own via the napa route. Dont know about changing the lower rad hose, all that is required for a diesel is to tap into heater hose, and run return line to coolant bottle. Unless there is something different about the ranger one of these should work.
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