Need Some Help!!! - Coolant Leak

[moneypitroush]

Good Afternoon,

New here on Stangnet, and am excited to be here finally after using the forums to help advance in my mustangs occasional issues. I have a 03 Mustang Stage 2 Roush and need some help with the cooling system. I have recently replaced coolant reservoir, upper radiator hose, thermostat, 3-row radiator and the cooling fan. I noticed a significant amount of coolant was being lost after driving for some time (like the whole reservoir after a few days of driving). I was working on my headlights (installed Hids) when i found the place where the coolant leaks from. However, i don't know how to access it. I'm thinking i have to replace the gasket or make a new one but i can't seem to find a way to access the bolts. in the pictures to the left of the alternator, under the thermometer sensor is where the leak comes from. Leak is coming from area pointed by green arrow. The whole thing is connected with the thermostat housing. Please let me know if you have any advice. Thanks!

 

[COramprat]

Could be the gasket or a crack in the upper intake. Either way the whole upper intake had to be removed to replace it.

 

[moneypitroush]

Thanks for the quick response. I guess taking the upper intake out will be my next task. Are the cracks visible most cases or are the like micro cracks?

 

[COramprat]

Depends but when running and at temp you should see where it is leaking

 

[moneypitroush]

It's leaking from where the arrow is showing. at cool and normal temp. i can hear it "bubbling" and can see it too. I think my manifold is fine but will still take everything apart. Won't hurt to change the manifold gaskets.

 

[robertsa]

There is a common leak that I had to replace my manifold to fix a here while back. It occurs when the o-ring between the metal and plastic pieces there blows out or when a crack forms in the plastic between the metal of the coolant crossover and the head. Mine had both issues; I believe the o-ring blowout may have led to the crack formation or vice versa.

 

[wmburns]

+1 on above. I have recently dealt with a similar problem on two Fords. One was repairable with RTV the other not.

Here's some more information that may help. Pay special attention about the Fel-pro gaskets between the plastic and the metal cross over.

Fel-Pro 35958 35957

https://www.stangnet.com/mustang-forums/threads/overheating.898063/#post-9051526

 

[moneypitroush]

Thank you guys so much for the help. The videos were a big help too! hopefully it's just the gaskets (fingers crossed).

 

[moneypitroush]

took everything out and was a bit surprised. Both thermostat gasket and other side of cross membrane the gasket was also shot. intake manifold to head gasket was also shot. And the manifold was broken as seen in the video in both places of cross membrane. Thanks for the help once again. Time to clean everything up, buy new intake manifold and put everything back in.

 

[robertsa]

Sounds good. Clean up those mounting surfaces and the valley good while you've got it gutted. It's also a good time to use some compressed air to blow out the spark plug wells. A lot of debris gets down in there over time. When mine was leaking, quite a bit of coolant made it down into a couple of them too.

 

[moneypitroush]

I sure will. Almost done cleaning everything up. Ordered a new intake manifold should be here by Saturday. Then till be time to put everything back in!

 

[moneypitroush]

Done cleaning up!

 

[Neuron]

Nice, who's manifold are you going to use?

 

[moneypitroush]

I bought the Dorman from amazon. Was going to get the one from AM but they look exactly the same

 

[Noobz347]

My tip would be to use meaningful thread titles when you create them.

You generally get more frequent and better responses when someone can read a thread title and know whether or not that's a system they are familiar with.

Please carry on, welcome aboard, and good luck!

I've updated your thread-title.

 

[robertsa]

Looking good. You'll be back in business soon.

 

[Neuron]

I bought the Dorman from amazon. Was going to get the one from AM but they look exactly the same

The Ford OEM piece must be pretty pricey I take it.

 

[robertsa]

The Ford OEM piece must be pretty pricey I take it.

It's a few hundred. I just replaced mine and put about 20 miles on it before deciding I wanted a different one. Boy I wish I could go back in time and stop that mess...

 

[Pacnwjim]

I bought the Dorman from amazon. Was going to get the one from AM but they look exactly the same

I just went through the intake replacing. My suggestion is do NOT use a Dorman intake manifold. Good chance you're going to have problems. Just google the problems people have had with the Dormans. You get what you pay for. I used a O.E Ford racing manifold. Cost is a bit more but you will only do it once. Good luck.

 

[moneypitroush]

I have read the reviews on the dorman intakes and know they had many issues with the intake prior to the 02 mustang when the cross membrane was still plastic rather than aluminum. I did more research on the one I got and people say that there is power loss and that I'd need to hit the gas more than before to get up to speed. I think I'll return the dorman and get the one from AM. Should've done that in the first place. About $50 difference