Hello,

My new to me, 2000 SD with the 5.4 has developed a coolant leak under where the heater hose comes into the water jacket on the passenger side of the intake.

Its not the hose, you can see it seeping from between the aluminum coolant crossover deal ( across the front of the intake ) and the plastic manifold.

Its not leaking hard, but you get the coolant smell, and a little is puddling in the valley under the intake.

Does a standard intake gasket replacement address this issue, or is there a different gasket involved here?

I not reading good things about this intake setup and many other things with this engine too. I'm beginning to wonder if I should have kept my 95 F-150 4x4 5.0L

Thanks

 

I moved this to the Modular V-8 section. Where I should have put it to begin with.

I don't see how to delete the post, so sorry for a double post.

 

So the leak is between the coolant crossover and the intake itself?

 

Yes, Its right where the crossover appears to bolt or mate to the plastic intake. Looks there are a couple of bolts come in from the bottom side to help sandwich it together with the plastic.

I see the PO has even put a little bead of RTV on to try to stop it. Must have held long enough to sell it to me. I did not smell any anti freeze after the test drive.

BTW, Thanks for the response, I've had no replies in the modular section. I have read all different scenarios for intake leaks and about some pipe that leaks under the intake, This is for sure on the top where the two pieces come together.

Thanks

 

I've never heard of the modulars leaking there. The pipe that goes underneath rots, the intake with the plastic crossover cracks (happened to the wife's Cougar and my '96 t-bird), etc.

Never that crossover. Is there a Ford logo and/or part number on the intake somewhere? If not, it might be aftermarket (Dorman?).

If it were me, I'd remove it, RTV it, and put it back together. Don't know if you're going to find a gasket for that.

Matter of fact, just checked around, you need to remove the intake, and the o-ring that sits in there is probably shot.

Here's a thread I found about the 4.6, but same idea.

If you're going to take it apart anyway, I'd look into a new intake.

Rockauto (one of our sponsors) has the Dorman replacement for $211.89

Dorman part number 615174, More Information for DORMAN 615174

Of course, you might find it cheaper elsewhere...

 

Yes, From all I've read, mine is not leaking in the normal leak place.

I actually wondered about the intake being a replacement. Becuase somewhere in my Googling last night, I came across someone saying you can't service the gasket normally on the Dorman intake.

So I'm gathering the intak gasket does not come up into this area?

Sorry about my lack of knowledge on this enigne, if it were a 460/351M/400/ 390/360 whatever, I'd be good.

I will try and find a number and take a pic to link on here if possible.

I saw no link for the 4.6 thread.

Thanks

 

It's separate from the "normal" intake gasket.

Coolant Leak on my Buddies 2002 Mustang - Ford Mustang Forums

 

OK I found a part number YL3E-9424-AD on the intake, which I then Googled. I found this intake on ebay. I see what appears to be contured o-rings on the front section of the intake, to seal this water crossover.

I am figuring there is no way to remove the crossover with the intake on the motor, because of bolts that come in from the bottom side, at the mounting surface of the crossover?

 

I looked at your link. The second person that had pictures made me think about my recent tune up on the truck. The #1 plug looked like it had been wet, little rust on it. That would be at the o-ring on the drivers side.

I'm not seeing a physical exterior leak on that side, but if the o-ring is puckered inward (like the one in the pictures, from your link), the water would go right into the intake port on #1.

 

So is it really leaking from between the crossover and the intake itself, or the crossover and the head?

 

It does not show that well in my pics. But yes, it is leaking where the plastic intake sandwichs with the crossover.

The top pic is from the (as your leaning in the engine bay) right angle. Thats the #5 cyl injector you see in both pics. Coolant puddling in the plastic area on the back side of the crossover. It leaks from the back side. PO had dobbed RTV in there to try and stop it, looks like.

It has to be the contured O-ring leaking in the sandwiched area.


I found a brand new ( not a reman) 2000 model V-10 for sale, only ran for testing. Hmmmmm

How much of that would be a bolt in?

 

You need the PCM, wiring harness (for the extra cylinders), and that's about it, I think. But the intake, exhaust, etc, might be different.

 

The full harness is on the engine now. I did not know how much would be direct bolt in. I've done 351M to 460's before, not too big of deal.
The V-10 has the intake on it & exhaust manifolds. Wiring harness to engine controls.

I know there would be engine mounts, Frame horns may be same for the modulars? Then like you said, PCM, radiator and or fan shroud, where the V-10 is longer. Transmission bolt pattern. I've read the modulars are the same, but I personally don't know. Then have to dress the front of the engine.

Ah, I'm to old to dream about crap any more.

 

Well its getting to me.

I figure I'll post the swap question in the V-10 forum.