Well this kinda sucks trucks in bad shape. I have a 99 and it seems to be using ic fluid. It has had the recall done before i bought it. Within the last month I have gone through a gallon! I imagine that the new one is leaking again, whether they just replaced it with another defect or not I don't know? Was there a time when they started the recall that they may have been just replacing with the same design?
Anyway I need to know what part #s I need to replace and where they are cheapest?
Sorry for the bad typing!
Thanks for any input.

 

If the recall was already done, then Ford would have to cover it under the "service parts warranty" usually around 1 yr. Good luck.

 

I also bought a used 99 L .

Do not run it with it leaking or you will be sorry. Unplug your pump, and cap off the tubes at the front of the manifold until you can scrape up the money to fix it. Do it before warm weather gets here. I drove mine several thousand miles without the intercooler and contrary to what some might say don't think I hurt a thing doing it. Just don't thrash it at full boost for more than short periods or tow things where you would be in high load boost situations. Fix it soon but don't panic or park it. IMHO

I found the best price here.
http://fordparts.com/

The part number is XL3Z-9424-AB Kit intake manifold kit

It comes with the upper manifold plate and all the gaskets you need.
You won't need to remove the entire intake manifold, just the blower and top section. It is a cake job that will only take you about 3hrs. (leave the left rear bolt in the supercharger when you pull it and make sure you have it dangling in there when you put it back in place)

It is a great time to check and or replace your spark plugs and you will need to add time if you do that.

The new intercooler was slightly different from the original one and is a little deeper.
The first couple years Ford replaced it with the same unit and they averaged around 18k miles between failures. The newer ones seem to be working out fine.

You will see lots of oil in the supercharger and lower manifold cavity. This is normal!!!!! Just get some solvent and wipe it out. I didn't bother with the super charger. The early rotors are teflon coated and you may also see a little flaking which is common. I wouldn't panic about that ether.

It is a great little truck so don't get bummed over this issue.
Good Luck
Greg

 

Thanks Greg that was more than helpful! I am ordering it today and hopefully installing it over the weekend. Also have some it22's to install so it should work out good. That is a great price compared to local dealerships.
Thanks again
Dan

 

Oh I almost forgot.
Lightning Tunner came to my rescue with this information that I will gladly pass on to you. Regaurding installing the S/C. I cleaned the bolt threads on a wire wheel and put them back in dry. If you lube them the torque spec would of course be lower...I didn't see the need. Nor did I use any thread lock. They sure did crack loose with a loud noise that scared me when I took them loose.

Here is the Tunner. All these guys are real helpfull

Greg, it's a two stage torque sequence on the install. First torque to 18 ft lbs, then torque to 33 ft lbs. Start at the middle bolts and work your way out. Bolts 1-8 in the sequence are the blower bolts, 9 and 10 are the two rear bolts closest to the blower, and bolts 11-12 are the far rear bolts. Hope this helps.


__________________

 

If you have used that much coolant be sure to change your oil and change it fast! Otherwise kiss those bearings goodbye. Keep it safe man. Goodluck on the install. -Mat-

 

I was looking on fordpartsonline and searched for that part # but found nothing. When i looked i found intake manifold lower w/supercharger $528, also intake manifold upper w/supercharger $332 are either of these what I want. fordparts.com wants 680 and was just lookin for a better deal.
Thanks for puttin up with my hassle!

 

"originaly posted by"
BlueOvalBolt
Senior Member

Registered: Nov 2000
Location: West Milwaukee, WI
Posts: 116
This was an Owner Notification Program from Ford to fix chronic intercooler leaks on 99 and 00 L's. The program number is "O1B81 - Intercooler" and the kit is part number SPO XL3Z 9424 A8 (titled "Kit, Intake Manifold) which consists of a replacement 10 row intercooler and an new upper intake manifold. This program expired in September of 02 so unless it is still coverd under the standard 3/36 warranty, there is not going to be any help from Ford. It's about $850.00 for the kit without labor.

Hope it helps.

 

Don't know why you had problems. I double checked my numbers.

Thats what I ordered and that's who I got it from.

The warraty BS ended last september so unless you have some inside pull plan on doing it yourself.

You can find all kinds of prices on individual parts put you can only by it assembled as the kit with the upper manifold. Finding part numbers and looking at prices is one thing. But finding that part in stock is another.

Don't worry about changing oil in a panic. That is misinformation also. What goes in your intake goes out your exhaust not in your oil daaaaaaaaaaaa.

We have been spraying water in our intakes (water injection) for decades without problems. It is the antifreeze that raises havoc with your O2 sensers and Cats.

Take your time, do it right, this is not the area to be cheap. Nothing about these trucks is cheap!

I just went through this whole thing that you are entering into. If you want to reinvent the wheel thats fine.

 

Don't quote me but I think that is it was a recall they will replace it again. Talk to the dealer. I had mine replaced twice. The last time they put the 01 innercooler in. Which is suppose to be better.


Suavy

 

Could someone answer a question for me. I have an '99 that
I purchased used with 23K miles on it. The intercooler was
replaced in November of '01. My impression is that it was
replaced due to a recall notice and not due to the original
part failing. My question is, how do you know when the
intercooler has let go? Do you get a Check Engine light due
to the coolant vapors in the exhaust gases?
Somebody on this thread suggested that it gets into the
crankcase oil. How?

 

I've got a problem, and it may sound stupid. I've got the blower off and now am gonna take the ic out, do i have to drain the ic fluid out completely? Also while the blower is off i'm gonna change the oil in it, i will get it from a pontiac dealer but how much is needed? so far so good. Thanks for the tip on the price ezgz but I need it now, luckily my dealer has one on the shelf says 970 but he'll give it to me for 850. Soap also said he may be able to get me 03 parts but haven't heard from him yet.
Anyway
Thanks to all

 

fcmiller- you can tell it is leaking when your wallet starts to scream! No seriously there is a ic resourvoir[sp] behind the fan shroud and to the right of the windshield washer tank, it is full of green coolant just periodically check that it is inbetween the lines. There are no lights to come on to tell you. When did you buy the truck?

 

It will not effect the way the engine runs durring normal driving and will not cause any engine lights or diagnostic clues.

One day you may just here some detonation under full throttle or see that the intercooler resevoir is low or empty.

All the silly thing does is cool the air that was heated up by the Roots style supercharger that we run.

Cooler air will hold more fuel molecules than warm air and that makes more horsepower.

It is just cheap insurance by ford so John Q public can drive it anywhere anytime.

The replacement intercoolers were built a little different.

It will not get into your oil unless you have other serious problems. Does air from your intake go through your oil? No
If your rings are worn or valve guides are shot it can gradualy contaminate things but not in a healthy engine.

Don't worry about it. Just check it every time you check your engine oil. (look at the resevoir)

If you do get a leak. Unplug the circulating pump ASAP that is a $300 Bosch pump and it won't live long if you run it dry. The seal with fail.

 

I had mine replaced three times before the recalled unit was installed - all this on my '99. Make sure that the unit put in your truck was of at least '01 vintage. I did drive mine with a leaky intercooler the first time around for a summer since I was stuck up in Michigan. On the second one that let go, they pulled the fuse to the pump. On the third, it sat at the dealer until all the parts were in and everything was replaced.
You will know when it begins to leak - always have a sweet smell, and the tank will go dry before your very eyes.
What gets me is that there are owners out there that never had this recall done... then they sell it to unsuspecting buyers... it's just not right.