A co-worker of mine has a 2000L which sure looked like another intrercooler leak, since the intercooler coolant level steadily dropped with no evidence of leakage. So I pulled the blower and the intercooler out. I would have expected to find a lake of coolant in the intake manifold, but can't find even a trace of it, and I even looked under the tablespoon of oil in the bottom of the manifold. Is it normal for the coolant to simply go through the engine and vanish? I'd expect some residue, somewhere. Help!

 

I've got to bump this up....

With all the intercoolers that leak, someone has to know the answer!

 

there is a special kit you need to buy.

If you buy another stock '99 intercooler it will leak. I don' t think they make them anymore.

If you buy the 2001 - present, the bolt holes are different and the lower manifold runners are different.


YOU NEED TO BUY:
the kit.

Perform 01B81 for leaking intercooler P05 repair
Cause: 33211 Perform 01B81 recall. Replace intercooler
01B81B 01B81B/ Replace supercharge intercooler sub-assembly
SPO XL3Z 9424 AB Kit, Intake Manifold

 

https://www.f150online.com/forums/sh...hreadid=174350

what is your E-mail address!

screw it... here's something to read


All Ford Vehicles have an Emission warranty for 8 years or 80,000 miles.
A leaky I/C will Fould your O2 sensors and clog your catalytic convertors.
This is a federal Law C.F.R. somethinhg or another, that Mandates Ford to ensure the Emissions of the vehicle is up to par for 8/80. While doing some research I have concluded this may be the best way to go. I have told about 10 people within the last week who have this problem the same thing. Hope it works.
READ BELOW.


> couple things to keep in mind.
> If the reservoir is leaking it is MOSt likely the
> I/C. which you can't see, the fluid is going
> directly into the combustion chamber. (NOT GOOD)
> also on my truck it fouled all the O2 sensor and
> clogged the Catalytic Convertors.
>
> I ended up paying $532.00 (parts) and i installed
> it.
> read below to see the details.
> Installation is quite easy and the dealership will
> give you step by step directions.
>
>
> Well first Ford can be a PITA about this.
> This is what I did:
> When my I/C began leaking this is what I did:
> Ford never had a recall per se. it was classified
> as a customer service campaighn to satisfy the
> customer. The NHTSA never issued a recall.
> Therefore it is up to Ford if they will replace
> itfor free.
> 1. post on all the boards to gather as much info as
> possible, Specifically who go theirs replaced since
> the cappaign ended, names dates dealerships etc...
> they set a "kinda precedent".
> 2. Called Customer services and was EXTREMELY nice.
> I used to work for Ford Credit and we logged all
> calls, they can pull up your vehicle be VIN and look
> at what was discussed the last time you called. If
> you **** them off, you will get no where quick.
> Customer service was of little help. I gave them
> all the info of others who have had it replaced and
> they said they would submit the claim and get back
> to me. They called back the next day and denied it.
> 3. Called Ford SVT, and got the campaign number (I
> have it somewhere if you need it) and asked specific
> questions. The intercooler is leaking becuz one of
> the welds on the intercooler is weak and it breaks
> and starts to spray I/C fluid in your combustion
> chamber (not good). They said I'd have to call
> Customer service to see if Ford would cover it.
> (already did that)
> 4. Got the number for the Arbitration/Mediation
> department for Ford. This is a great service IF
> your car is under warranty. basically if you think
> Ford should fix it and they don't you go here and
> they come to a solution. But as i said, this only
> applies if your car is under warranty. so that was
> another dead end.
>
> 5. Contacted the NHTSA. (national Highway
> transportation safety administration) and filled out
> a complaint. My complaint was that the I/C fluid in
> the combbustion chamber could cause the engine to
> Vapor lock. If I'm driving down the Highway at
> 80mph and the engine locks, there goes, power
> steering, power brakes (still have manual) and in
> extreme cases could spin a bearing (major problem
> with engine) and lock up the engine. They were
> impressed, (I gave them all my research, data,
> Ford's campaign number) they especially liked that
> FORD knew about this problem and had a Campaign.
> They sent me the form, I typed up a few more pages
> of specific description and sent it in to them.
> They are investigating it, but Who knows when it
> will be solved. (that is still on gonig) It isn't
> a moot issue since I got it fixed, because this is a
> safety issue. THEY ARE STILL INVESTIGATING IT.
>
> 6. I did NOT try this BUT: The manufacturer of a
> vahicle is responsible for the emissions of that
> vehicle up to 75,000 miles. the Leaky I/C (on my
> truck) has plugged the Cats and fouled my O2
> sensors. Therefore This thing is guzzling gas like
> crazy and spewing everything into the atmosphere.
> (emissions) Here in Michigan, we don't have
> emission testing. I'm not sure who to contact but
> you can file that the defective part (leaky I/C) has
> caused severe emission problems (don't give them
> your VIN, because it could hurt you in the end) and
> that Ford is responsible for the emissions up to
> 75000 miles. My truck is a '99 and just turned
> 13,000 miles. So it was covered, but i was so fed
> up at this point, I didn't pursue it,. I should
> have though...
>
> 7. I called every dealership in the state that sold
> SVT and explained the situation. I finally found a
> delaership who had the part sitting on their shelf
> for a year and wanted to send it back to Ford. Ford
> would onl;y give them what they paid for it. SO
> they sold it to me at COST. $532.00 plus tax. I
> also had that delaership print off from the srevice
> manual step by step directions on replacing the I/C,
> complete with torque spec and all. It is an easy
> job and takes about 2.5 hours.
>
> 8. MAKE SURE YOU GET THE RIGHT PART.
> there are 3 parts out there that are the same thing.
> 1. the original one that will leak.
> 2. the new version ('01 and newer) that doesn't
> leak and is more efficient, BUT doesn't fit 99-00
> becuase the bolt holes WILL NOT line up.
>
>
> 3. The upgrade KIT. this is what you want!!! It
> upgrades the 99-00 version to the 01-present
> version. and is a complete kit! Again i don't have
> the part number with me but I can get it if you want
> it. the kit comes with upper and lower manifold
> and the inner coller itself. It looks intimdating
> to do, but it is really not that bad at all.
>
> Now, You are gambling if you buy a used one. A
> leaky one CANNOT be REPAIRED, trust me I went
> everywhere looking for someone to fix it. the metal
> is just too thin, and if the weld breaks, the metal
> weld could end up in the combustion chamber.
>
> Ford customer service will submit on your behalf a
> resuest to have Ford pick up part of the bill.
> Don't hold your breathe it will be turned down.
>
> Ford's campaign to fix this ended a year ago, and
> they are not going to extend it, (unless NHTSA comes
> through)
>
> THIS IS WHAT I RECOMMEND TO DO
>
> 1. ask the local SVT clubs (michgan =
> www.miloc.org) and ask for SVT friendly dealership
> that may sell the part at cost. Bite the bullet and
> get it. Ford only made a certain number of the
> "kits" and once they are gone, they are completely
> gone.
>
>
> Now if someone tries to sell you one from a '01 or
> newer, don't waste your mony, it won't fit.
>
> youll have to buy the Upper, lower manifold, the
> intercooler AND THE BLOWER! they are on Ebay like
> this, but sell for a lot!
> the bolts on the blower are also different, so a '01
> and newer blower will not fit a 99-00. Nor will a
> harley blower!
>
>
> Luckily hI have another car to drive, so the
> Lightning sat for a while I I tried all avenues.
> Ford screwed us, plain and simple, and it is for
> that reason I'm not buying another one.
> I keep the Leaky I/C on a shelf to remind me of the
> pain in the *** hassle I went through with Ford.
> Heck Dodge has the 7/70! (sorry didn't mean to rant)
>
> Try the Emission route and let me know how that
> turns out.
>
> GOOD LUCK.

----------------------------------------------------------------------------------


Ford made 3 intercooler kits.
1. 99-00 Leaky stock intercooler
2. 99-00 Non-leaking stock intercooler with SPECIAL manifold 10 row
3. 01-present Stock intercooler 10 row

Now, IF you get a 01-present intercooler it will not work with your blower. you MUST have a -01-present blower.

The KIT that ford made to correct this problem is EXTREMELY LIMITED AND VERY HARD TO FIND. you are going to have a hell of a time locating one. If someone knows what they are worth, expect to spend a pretty penny!.
If you can find a dealership that has one the retail is over $700.
It si one big box that has upper and lower manifold and the intercooler.
the exact part numbers can be found by using the SEARCH buttong on top and type in intercooler.
I've posted about this a thousand times.

Read my post above on what I did and went through.

So your truck can have the upgraded intercooler with the '99-00 blower, it simply has the KIT on it.
(same thing my truck has right now)

 

My '99 L had the I/C leak and it was very minor... there was no residue build-up. It just vaporizes.

 

Thanks for the info guys. My main concern was that I found no residue. I suspected the vapor may have been fine enough to be sucked into the cylinders before it had a chance to condense.

As far as the replacement is concerned, I do feel Ford is denying what should be valid claims under the emissions warranty. But I'm lucky enough to actually have a complete late manifold and intercooler assembly which I'll be installing accordingly. I noticed that there is a very significant difference in the runner configuration of the two manifolds in that the late manifolds have fully seperate runners and the early manifolds are much more of an open runner style. The new manifolds should create more torque at a lower point in the curve. I'll post a response as soon as we know.

 

Keep an eye on your catalytic convertors.

that I'C KILLS them.
!@#$%

 

I-menace: This whole thing sure looks like it has the makings of a class action..........

I'm lucky in that I had the parts to fix it on the shelf. Many others are not. I'd rather have my fingernails pulled than to have to go through the torture of convincing Ford that they are responsible and then hoping the repair tech has actually done one of these before. There's a really good thing in my being one of the best mechanics I know: I trust my work and I do it right.

 

Funny how literally THOUSANDS of '99-'00 intercoolers have leaked and only a few people had their O2s or cats replaced...

 

It is isn't it?

 

i have a 2000 L and i had the same problem. intercooler losing coolant with no evidence of where it went. i pulled the intake manifold and didnt find much coolant in the intake but it was obviously going threw the engine and out the exhaust, not a good thing. my brother in law (ford senior mastor tech) found on a ford web page that they know about the problem and theres a kit that you can buy basically its a redesigned version of the stock intercooler. i bought the kit and i havent leaked a drop since, its been like 300 miles. however i gernaded my engine on the interstate on the way to san diego. but i would definately recomend getting the kit, coolant leaking threw your engine is not a good thing, probly had some part in my engin blowing up. but i drove from virgina to az, leaking coolant all the way before i fixed it, and it was a week too late. good luck i could get the part # for the kit if your interested. shoot me an email ak2azyz4ever@yahoo.com

 

btw the kit comes with an 11 row i/c. upper and lower intake manifolds and all the gaskets. it wasnt hard to find got the kit the day i ordered it, if you have trouble finding one let me know ill get you one