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Another V-6 collant leak

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Old 02-14-2007, 03:41 PM
magoo50
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Another V-6 collant leak

I rescued my son from the interstate this morning when his 2001 F-150 overheated. I was able to trace the leak to a small (approx 5/8 in) metal tube that is in the forward part of the intake manifold. It appears to be a heater hose supply/return but I could be wrong. The tube is leaking on the back side where it exits the maniflod and sprays several small streams when under pressure. I called Ford and apparantly this "tube" is force fit into the manifold rather than screwed in. I was told in order to fix this leak I would have to replace the entire manifold to the tune of $710.00.
That is a load of C--p. I suspect if I had the manifold in my lap I could figure out a way to thread a new pipe in like Ford should have but---It isn't in my lap. My question is, has anyone run into this before? Has anyone tried using JB Weld or something like it to repair this problem? By the time I get answers I may be able to report on that myself. HAs anyone else modified the maniflod to accept a screw in replacement? I thought I would find a rusted up coolant system but it is really very clean. This has been the only coolant leak so far. Any comments?
 
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Old 02-14-2007, 07:46 PM
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Find the supply to the intake and the return from the intake. Trace the two lines back to the origin and replace with a new line effectively short circuiting the loop (i.e. bypass the intake manifold).
You might be able to butt the two ends together with a very smaller piece of copper tube.

My 2000 was done this way and ran thousands of miles with no ill effect seen.
 
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Old 02-14-2007, 09:17 PM
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Thanks Brian, Am I to assume this is a water jacketed intake manilfold? If not what would I be by passing exactly?
 
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Old 02-14-2007, 09:34 PM
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Correct.
For reasons I do not know, coolant is circulated through the intake.
I have heard to warm the intake air.
I have heard to cool the intake air.
I have heard to cool the intake manifold.
I do not really know.

I just know mine was bypassed by the mechanic when I had my lower intake gaskets replaced and I could never tell any difference in any aspect of engine performance or MPG.
 
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Old 02-15-2007, 07:10 AM
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That is interesting. I believe you about by passing the manifold and that will be the first thing I do. You have my curiosity though and I am wondering why in the world they went to all the expense to cool/heat the intake. Does anyone know the engineering behind it?
 
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Old 02-16-2007, 09:14 AM
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JUst a follow up to anyone interested. I pulled the intake to clean the leak and found it to be too bad to repair with JB Weld. So I did what Ford should have done in the first place and threaded the manifold to accept a fine thread copper tube I made up. Worked like a charm. This is not real easy to do when laying on the engine but sure beats pulling the maniflod.
 
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Old 02-23-2007, 09:54 AM
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Not to sound stupid but, is the manifold al? My 99 was and if so won't this cause a corrosion from dissimilar metals? and make the problem worse.
 
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Old 02-23-2007, 11:55 AM
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Probably will so I will be replacing it with an aluminum tube. I was using what was at hand. The repair did come out ok though.
 
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Old 02-23-2007, 12:37 PM
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Good, I was thinking of my water heater at home. The sears installer did not use dielectric fittings between the Hard copper and water heater and it caused the tank to leak.
 
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