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?

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.

Thanks Brian, Am I to assume this is a water jacketed intake manilfold? If not what would I be by passing exactly?

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.

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?

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.

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.

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.

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.