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Old 09-30-2010
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Coolant Leakage Problem

Wednesday, I drove my truck as usual for the whole day pulling the lawn mowers and such (SSDD). However when I got home I cleaned out the throttle body and intake just for some 100,000 maintenance. After this I decided to mess around with the throttle to see if I was getting any better response which I was. I shut my engine off and I could smell the rank smell of coolant. Great...so I jacked the truck and low and behold coolant and the nasty water had shot all over the lower part of the engine along with the frame. Took it over to my granddads and we ran the **** out of it (continuous high RPM revs) while parked and more coolant and water came out. So we put it on the high lift and noticed the majority, well what we can tell the majority, of the coolant and water was coming from the thermostat on the water pump. So we figured it was a bad seal or something so we let it rest till today. We took the thermostat off today and replaced the seal. However more coolant and water from somewhere is still coming out. As of now the entire intake, throttle body, and intake manifold is off. Oh and other good stuff, there's seems to be a tad bit of oil in the intake itself. All of this to say, has anybody had this problem before? Any help would be greatly appreciated. because as of now were kinda stuck besides taking the engine apart more....
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Old 09-30-2010
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did you check the rubber hose from the block to the theromstat houseing.. look over all the hoses good for leaks are streched spots are holes... water pump may be going... em heater control valves are bad to leak too..
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Old 09-30-2010
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look at the lower thermostat housing that might be where the leak is coming from as far as oil in the intake its prob. a little oil blow by clean or replace the pcv valve and check the hose that connects to the pcv valve and runs to intake. Thats just what is sounds like to me and I have had this same problem. Good luck
Justin
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Old 09-30-2010
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We looked at all the hoses on the underside of the truck, whether it being off the radiator, block, heater, etc. No problems but we are going to replace them anyways. But I will look into the heater control valves. And I hope its not the water pump but it could be. What kind of money are we looking at to replace the water pump if need be? Would you recommend a new one if needed? However the truck never over heats even when this problem came up. When I was revving it up in the driveway with the heater on or not it didn't matter the temp stayed the same. And the coolant reservoir dries up like every week too. Thanks for the help though man.
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Old 10-01-2010
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Finally found the problem today after some tedious and cuss worthy work. On the top of the engine directly below the throttle body is a major plastic junction which holds the thermostat, a hose for coolant, and two sensors that control something. This piece seems to be put together in two pieces that are held together by some kind of adhesive or gasket. In some places the gasket/adhesive was gone and thus causing the leak. This would also explain why the coolant reservoir keeps drying b/c this junction could have been leaking for a long time without me knowing and finally gave way this week. So we just replaced the junction and drove it around and revved the truck up several times to see if the leak persisted. Next week I am going to replace the PCV valve cause I have already replaced the EGR and EGR control and this might just be the next step to stop the small amount of oil in the intake ,and I am going to take the truck to get the undercarriage and lower engine to be steam cleaned to get all that crap off. Luckily parts is all I had to pay for b/c my granddad and I did all the work. No telling how much this would have cost to be done at the mechanic that we taken it to or even Ford.
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Old 10-07-2010
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I am in the middle of the same repair. However i took the lower thermostat housing off without removing the intake manifold It was really tight coming out and i will have to be Hoodini to get it back in w/o taking the intake off. Has anyone ever accomplished this?
The ford parts guy said this is a common occurance. $150.00 bucks for parts.
Answer to your water pump price same parts guy said $165.00.
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Old 10-11-2010
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In my opinion try just taking the intake tube and throttle body off and trying your luck that way. But yeah the guy at Ford was like oh yeah this was common occurrence too. I was like ok, why in the hell is it made that way if this happens alot? He didn't have an answer lol. However back to the repair, I took the intake manifold off without really knowing if that was needed or not. You could try what I said, but if no avail then take off the manifold. Ha I was dumb and thought let's just take all this other crap off too, like the computer harness, coil pack, etc. That def did not need to come off.
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Old 12-01-2010
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Been there, done that

I just went throught this with my 2005 Edge. The thermostat housing was leaking into the intake valley.

You do need to remove the intake manifold, but it isn't that hard. There are some really good instructions on Alldatadiy.com if you have an account.

Be careful of those two sensors on the housing. They have an O ring, which will likely leak when put them back in. You are better off replacing them. I still have one issue. I replaced the housing, seals etc. and now the truck runs great with no coolant leak, but the temperature guage goes to hot right after startup and stays there. Been to Ford to verify that I have the sensors in the correct hole and all. Everything is fine in that respect. The one guy at Ford told me I probably had an air pocket in the system and suggesting running it with the radiator cap off to purge out the air. Well, I was skeptical anyway and of course it didn't work and leaked coolant on the floor while running.

Anyway, just be careful. You will need a Torx 30 bit to remove the intake manifold. Get those instructions. It will save you a ton of time.

If anyone has a suggestion about the temp guage issue, I am all ears.
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