Great work Gas...... Thanks for shareing.

Robert

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00 Roush Silver Lightning
00 Roush Expedition
98 Roush F-150
98 Bell Tech GMC 454 Daully
Collector of:
Watches, Zippo Lighters, Nikon Ftn Cameras.
High End Home Audio
Sponsor: Several Go-Kart Drivers. 1999 250cc SuperKart National Champion Joe White Jr.

E-Mail: gpkart@aol.com

 

PB,

Excellent post!

It realy helps to be able to visualize the problems we are having.

Nice Job!

adp
#1530
Black '99

 

Very nice to actually see that sucker! Thanks!

Now, if the "original" intercooler is in fact being updated due to problems, then I believe we are all entitled to the update regardless of whether our warranty is used up or not (even if our original IC doesnt break down until after 36K). Sort of like a recall. Right?

Mike

 

Excellent post PBGas!!! Thank you so much for documenting this for all of our bennefit! Now, how do I get my hands on one of those Escort wagons, are they a limited production item? j/k

Thanks again!,
Jake...

 

PBGas,
Excellent pix, thanks for the info.
Keep up the good work
Jim

 

Hi Guys....

I made it to work this morning in my stunning forest green Escort Station wagon. Took me a lot longer because there is absolutely nothing under the pedal on this thing ;-)

I will post the part numbers for both intercoolers, the old and new one. Then we can go from there. I am going to phone SVT this morning and start the complaint list. Hopefully we can avoid this crap again. From what I saw on the computer system, the new one is an UPDATED one for sure. It has a different part number. The price in Canadian $ for the old one is about $567.00. The new one is about $1023.00. How they get an extra 500$ out of that one is beyond me....

BABolt....feel free to use the photos!

Noelvm....part numbers will be posted by the end of the day today.

What04.....I have had no problems as of yet without the plate on the front. They just don't seem to bother trucks as much around here. They seem to go after the rice burners alot more for this.

Paul G.

 

5/3 8:30 AM CST. Just got off the phone with Matt at SVT. They were taking bets on who would get the first call on the intercooler. Evidently someone is reading our posts. GOOD!!! They checked out the two numbers in the supply system and said that the other number is for the 2001 Lightning intercooler and it is not interchangable with the 99-00 intercoolers.
The problems with the current intercoolers have been identified and the intercoolers in the system now are suppose to have the fix.

That's what they told me.
noelvm


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99.5 Red Ligntning, Syn Oil, Downs air filter, Bugflector, G&H Lens covers,
70 Vette LS-6

 

Good one Noelvm.......!!!!

I received a call from the guy who was working on my truck as I requested part #'s. He called me at about 8:50AM. He told me that the part number was from the 2001 units. He says though on his computer that it is being listed as an updated part # and that is why he gave me for info. Regardless of this I called SVT at about 9:45 and they told me that they had been expecting a call about it. Apparently noelvm beat me to it!!!! Good one Bud!!!!

so.....in essence, it looks like things will be ok after all.

I have to wonder what they changed in the new part # for 2001. They weren't at liberty to say what the extra horsepower is for the 2001 trucks. I'd imagine that they will be bumping it up to about 400 HP but who knows for sure, eh?

Anyways, all is resolved and I feel much better now.
sorry for the mis-information on this part....my apologies....

Paul G.

 

Noelvm....

You said they ordered you plugs?

Did you get a chance to take a look at the old plugs? Mine were actually ok. There was absolutely no fouling in them and they looked in perfect condition. The part that concerns me is the O2 sensor. I think that is should be replaced but until I get a code come up on the computer, they won't. Also, I wonder what kind of damage (if any at all) that my Catalytics have had......

I guess I will probably find all of this out after the truck is out of warranty. The reason why I am worried is because I am actually going to keep this truck for a long time. I like it, I enjoy it immensely and want to get the most out of it without having to worry about it.

Paul G.

 

Great pictures! I have to wonder what Ford is going to do about the existing problem at hand. My truck was built 3/2000. I really do not know what intercooler I have. After looking at your pics and doing a little research, I feel they do have a problem based on the number of failure reported this early in the trucks life. I am not an automotive engineer but i have 15 years experience working with fluid systems, and I have a pretty good understanding of heat exchangers because I am a reactor operator at a comercial power station and that is what i get paid to do. I plugged some numbers and a conservative temperature to the intercooler is around 420 degrees F at 9# boost. That is a hell of a thermal transient on the cooler. This cooler is continuously heating up and cooling down as you get your boost up and then let it go to a vacuum. this stresses the cooler because it is continuously expanding and contracting. Based on the composition of the materials, if they do not expand and contract together you can have problems. After looking at the photos it looks like the coolers are failing at the tube sheet. that is where the tubes connect to the distribution manifold. If the tube sheet and tubes do not expand and contract together, you can have leaks. Also these coolers can be heated up at a moments notice and then cooleed down quickly by getting off the throttle, that is a hell of a thermal transient{ 420 to 200 degrees f.} Also remember this cooler is going thru this cycle thousands of times in a cars life. The bottom line the intercooler has to be very tough and durable to be expected to last. I think Ford has a problem and I would be willing to meet them half way financially for a good durable inter cooler that will last in my truck. Believe it or not it takes good engineering and good material to produce a good heat exchanger that will last and transfer heat. The part I really hate is I have to let the local yahoo at the ford dealler tear into my truck. I personally feel, they do not take their time and do it right the first time.

 

Engineering is part of the reason I paid $1,000 over window sticker for this truck. I expect FOMOCO to hire competent engineers. Did the Eaton blower on the T-bird have an intercooler?
If this new intercooler, catalytics, or 02 sensor goes out, I will look to Ford to make it right reguardless of miles. The intercooler should last just as long as everything else. They took three years to build this truck. It's not suppose to be something thrown together by a bunch of guys in their garage over the weekend. It will be a sad state of affairs if an otherwise outstanding vehicle becomes the scourge of the earth and something no one wants because the intercooler can't be fixed. There are numerous cars and trucks that have visited the crusher before their useful life was done because of uncorrected design flaws. I hope this truck is not one of them.
Hey SVT, print this out and please give it to Mr. Scarpello.

Respectfully,

Noel Mc Gaughey

[This message has been edited by noelvm (edited 05-03-2000).]

 

They ordered plugs as a percautionary move because they are not a stock item and once the engine is torn down, if the plugs warrant replacement they wanted them in hand. The 02 sensor is evidently a generic item that fits many vehicles and they told me that it was a stock item. My leak is not bad and I am still driving my truck. My parts were suppose to be ordered yesterday. We'll see how long it takes. If you have looked at this engine plug removal is not a fun job. You have to remove the fule rails just to get to them. Evidently, the fact that they should las 100k was justification for not making them easier to remove. Fords current procedures is to determine the leak is not hoses and dye check, them disconnect the intercooler pump and order the parts. If your leak is real bad they may not want you to drive it. Mine is leaking about a pint a week. Some have reported gallons a week.
noelvm



[This message has been edited by noelvm (edited 05-03-2000).]

 

When will they have a recall? If its the metal differences causing the problem, then they are all going to leak! Sounds like I might as well go order one for my stock so I can fix it myself. Noel spoke of a lawsuit, is that what it takes to get Ford and SVT to get our trucks right? Why wait for them to break, fix them now. I leave on a trip on the 13th, am I going to blow my vacation because my intercooler its't working right and spend time at a Ford Dealer somewhere in America? Sorry guys but this stinks to me.

PBGas: were the other trucks there for the same problem, or were they new trucks? Looks like 2000 models.

[This message has been edited by 1BADTK (edited 05-03-2000).]

 

NoElvm....

the drivers side plugs aren't too bad to remove. I actually was able to take the first two out to have a look and see. When I get my truck back, I'll post a pic of the plugs along with a part #. As far as the gap goes, the first two were right on!!!!! I was also very impressed with the workmanship on the manifold itself. You could eat of this thing compared to the nasty "casting flash" that was all over my LS1. Someone mentioned that they checked all of the plugs and the gaps were way off....I hesitate to comment on this because I hope they had a lot of time on their hands to do this because as you said that passenger side is a pain with the fuel rails in the way.
Since they had to find my problem, I left the truck and it was kind of pointless for them to reassemble it. I didn't have a bad leak at all, but it was a leak nonetheless. Those that are leaking more than a pint are really risking doing more damage. I still want them to replace the sensor because in reality, the sensor may now be somewhat damaged due to the coolant. Regardless of how much damage, they should do this and not have to wait till the truck shows a code.

1BadTk......don't panic yet....lets all monitor how this new one holds up. I am going to keep a real sharp eye on it this time. Those trucks were 2000 models!!!! They always have a nice selection! I bought the last one back in September 99, so I was lucky.

Paul G.

 

Some great points. I would be willing to pay for something that is effective and durable. That is a lot of heat under there. It's not too much of a big deal to remove the actual piece in question. I am definately adding a bottle of that water wetter stuff just to hopefully keep things a bit cooler. Not sure if it will do anything but it is worth a shot.

Paul G.