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  '94 to '04 -- The SN95 Mustang
  Mysterious Coolant Leak on '96 GT.......

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Author Topic:   Mysterious Coolant Leak on '96 GT.......
Boss Hoss
Gearhead

Posts: 239
From: Georgia
Registered: Mar 2001

posted 01-21-2004 10:23 PM     Click Here to See the Profile for Boss Hoss        Reply w/Quote
Hello to Everyone!

I'm a longtime reader (and once-in-a-while poster) to this website, and once again I must turn to you all to help me with a Mustang problem!

My 1996 GT has a stubborn coolant leak. I have traced the coolant leak to the SHORT heater hose where it fastens to the inlet on the rear of the intake manifold, passenger side. I replaced the heater hose with a temporary cut-to-fit hose while I wait for the correct hose to arrive at my Ford dealer. I got new hose clamps and REALLY tightened them down HARD but I still get a leak!

I know for a FACT that the leak is NOT coming from the hose that fastens to the engine block underneath the intake manifold, which seems to be the more common cause of coolant leaks coming from the rear of the engine. I have small hands and I was able to reach down past the alternator and feel the hose connection under the intake manifold when the engine was cool. It was bone-dry.

At this point, I am ready to conclude one of the following:

1) There is a crack or other type of flaw in the inlet coupling that attaches the heater hose to the rear of the intake manifold.

2) There is some sort of blockage, either in the heater core or in the intake manifold water passage.

3) There is a crack in the intake manifold itself.

I really don't know how to determine the cause of the problem, BUT IT'S DRIVING ME CRAZY! I am currently waiting for the correct heater hose to arrive and I will install it and hope for the best...BUT...

Has anyone had a similar situation with their GT? Can anyone offer me any suggestions?

SteveLaRiviere
Administrator

Posts: 48752
From: Saco, Maine
Registered: May 99

posted 01-23-2004 09:28 AM     Click Here to See the Profile for SteveLaRiviere        Reply w/Quote
I thought I had heard of a 'silent recall' concerning intake coolant leaks. I think they cracked, in fact. You are way out of warranty, but you should see if your dealer knows anything about it.

------------------
'70 Mustang Mach 1 351C 4V/FMX/3.25 Open
'70 Mustang Convertible 250 I6/3 speed/2.79 Open
'72 Mustang Sprint Hardtop 351C 4V/FMX/4.30 Trac Loc
'94 F-150 XL 5.8L/E4OD/3.55 Limited Slip

Moneypit
Gearhead

Posts: 167
From: Sacramento CA
Registered: Jun 99

posted 01-23-2004 01:08 PM     Click Here to See the Profile for Moneypit        Reply w/Quote
If you haven't had the intake manifold replaced yet, I'd bet it is cracked. There was indeed a "silent recall" for it. I never could track down my coolant leak until the manifold went kaput and dumped all my coolant. It sounds like you are talking about the trouble area if I remember correctly.

SUBMARINER MUSTANGER
Gearhead

Posts: 1474
From: Grandview, Missouri
Registered: Jun 99

posted 01-23-2004 01:29 PM     Click Here to See the Profile for SUBMARINER MUSTANGER        Reply w/Quote
Your coolant IS leaking from that fitting. It's very common with that intake. They also leak from the front and there IS a recall and sometimes these recalls are extended for time but I believe there is a mileage limit. Check with your dealer or better yet either email your VIN and mileage of your car to me or post it here, and I can check right quick for you!! As a Ford technician, I can access that information through OASIS right here online. Let me know if I can help you out.

[This message has been edited by SUBMARINER MUSTANGER (edited 01-23-2004).]

SUBMARINER MUSTANGER
Gearhead

Posts: 1474
From: Grandview, Missouri
Registered: Jun 99

posted 01-23-2004 01:44 PM     Click Here to See the Profile for SUBMARINER MUSTANGER        Reply w/Quote
Here ya go! Got this from Ford. It doesn't look like there is a mileage limit, but you may be out on time depending on what your warranty start date is. I can get that for you as well if you need. The recall only mentions a crack behind the alternator, but OUR dealership replaces them if they're leaking anywhere. Hope this help. Good luck!


Ford Motor Company
P.O. Box 1904
Dearborn, Michigan 48121


97m91 April, 1999

Your Vehicle Identification Number: 12345678901234567


Mr. John Sample
123 Main Street
Anywhere, USA 12345

Ford Motor Company is providing a no-charge Service Program Number 97M91, to owners of certain 1996 through 1998 Crown Victoria Taxi, Town Car Limo Prep & Livery Package, 1996 and 1997 Thunderbird, Cougar and Mustang vehicles equipped with 4.6L SOHC engines. This service program provides additional coverage for the intake manifold.

REASON FOR THIS PROGRAM

Fatigue cracks may develop in some of the composite intake manifolds used on the 4.6L SOHC engines installed in the affected cars. This condition may result in engine coolant leakage which, if not detected or ignored, will cause engine overheating. Complete loss of coolant may result in engine damage or engine failure.

WHAT WE WILL DO

If the engine of your car should develop a coolant leak at the intake manifold cross over coolant passage, located directly behind the alternator, your dealer will verify the condition. If the coolant leakage is from the location described above, your dealer will replace the engine intake manifold assembly free of charge.

This no charge coverage is available for 7 years from the vehicle's warranty start date (no mileage limitation) and is automatically transferred to subsequent owners.

WHAT YOU SHOULD DO

PLEASE KEEP THIS LETTER. If your car's engine intake manifold should exhibit the above condition within the 7 year coverage described above, contact your dealer. Show the dealer this letter. The dealer will replace the intake manifold assembly after verification of this specific condition. If you should lose this letter the dealer will still honor the provisions of this program.

REFUNDS

If you paid to have the engine intake manifold replaced due to a leak at the cross over coolant passage before the date of this letter, Ford is offering a full refund. For the refund, please give your paid original receipt to your Ford or Lincoln Mercury dealer. To avoid delays, do not send receipts to Ford Motor Company.

CHANGED ADDRESS OR SOLD THE VEHICLE?

Please fill out the enclosed prepaid postcard and mail it to us if you have changed your address or sold the vehicle.

We are taking this action as part of our ongoing efforts to maintain owner confidence in our products. We hope this program will confirm your continued satisfaction in your Ford-built vehicle.


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

CPR ? 1999 FORD MOTOR COMPANY
Published By: Recall/Service Programs Department


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Sub Stanger/1990 LX 5.0 convertible (AOD to T5 conversion....completed)& the meat in the famous "SUB SAMMICH"!

Past Mustangs: '84 GT 5-speed; '91 GT auto; '70 M-code Mach 1, grabber yellow; 2 '95 GT 5 speeds, totalled first one; '94 6-banger, wifes; '89 LX 5.0 vert, '90 LX 5.0 hatch, '69 M-code Mach 1, 4 speed.

[This message has been edited by SUBMARINER MUSTANGER (edited 01-23-2004).]

Ked
Moderator

Posts: 9683
From: Fayetteville, N.C.
Registered: Jul 99

posted 03-04-2004 09:20 PM     Click Here to See the Profile for Ked        Reply w/Quote
Hey Craig,

Nothing for the '94?? I've been plagued with a coolant leak also and can't seem to find the stupid thing....

SUBMARINER MUSTANGER
Gearhead

Posts: 1474
From: Grandview, Missouri
Registered: Jun 99

posted 03-06-2004 10:32 PM     Click Here to See the Profile for SUBMARINER MUSTANGER        Reply w/Quote
quote:
Originally posted by Ked:
Hey Craig,

Nothing for the '94?? I've been plagued with a coolant leak also and can't seem to find the stupid thing....


Hey Ked! The intake on the '96 and later is completely different than yours. It's half plastic/half metal. The plastic goes to shyt and starts leaking. Sounds like you just need a good "pressure test" I checked out the TSB for your car and saw nothing pertaining to coolant leakage, but there were 110 TSB's, so if there's anything else you're concerned about, give me a shout and I'll look it up for you!

------------------
Sub Stanger/1990 LX 5.0 convertible (AOD to T5 conversion....completed)& the BUN in the famous "SUB SAMMICH" in Atlanta!

Past Mustangs: '84 GT 5-speed; '91 GT auto; '70 M-code Mach 1, grabber yellow; 2 '95 GT 5 speeds, totalled first one; '94 6-banger, wifes; '89 LX 5.0 vert, '90 LX 5.0 hatch, '69 M-code Mach 1, 4 speed.

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