Ok Buds.....I went over to the dealer to check out how the work was coming along with my truck. I found out some very interesting information and I was able to snap some pictures of what REALLY is going wrong with many of our intercoolers. I had no idea what it looked liked and I hope this helps others to diagnose their problem with coolant loss in their intercooler resevoir. The whole intercooler unit is a set of tubes set into a rad type element that is cast into a mini-manifold that sits under the supercharger. An interesting and expensive setup. The blower simply unbolts and pulls straight off of the top. The good news is that the coolant blows out of the exhaust. It can't head down to the bearings due to the lifter valley being in the way. It definately is a problem and you should fix it. The pictures are obviously from my truck. Here is the catch. Ford has 2 different part numbers for the intercoolers. The first part number is the original intercooler for these trucks. The second number is an updated version which is currently NOT RELEASED yet. They have the parts but are not releasing them because they want to use up the first set. My tech even tried to order it with me standing there through their OASIS system (this is their on-line database) and they wouldn't let him. He also called for me. My complaint is going to SVT, not that it will matter much, but if a few more of us get involved, it may do something. So, in essence, my intercooler will probably leak again. Hopefully by that time we will have the updated part which is about 500$ (Canadian) more.

Enjoy the pics and let me know your thoughts.
Thx .

Paul G.

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

 

Here is the first pic of the front of my truck just to show that the blower is actually missing.



[This message has been edited by PBGas (edited 05-02-2000).]

 

[This message has been edited by PBGas (edited 05-02-2000).]

 

Here is a closer photo of the cracked coolant core. Look at that S.O.B....it's even gleaming a smile at me while the sun is shining on it. For this I have to drive a 99 Escort Station wagon for a week!!!! S$%T!!!! ;-(

Anyways, you can also see the two hoses from the intercooler behind and on top of the intercooler intake.

 

 

and finally for the finale, a couple of extreme closeups.....you can really see the green area where the coolant was leaking.

 

Alas....that is it folks. I hope that you folks appreciate this. However, I do it only for the reason to help someone else out as I have been helped here many times. This is a great board with a great bunch of people.

A key area to also check is your oxygen sensor on the drivers side near the oil filter. If it is grey then there is definately a problem. (Thx Sal!!!)

For this I have to drive a 99 Escort Station wagon. Boy do I feel special in the morning on my way to work. JOY ;-(

but I look at the following bonus pic and I feel much better again! At least my truck won't be sleeping alone! Let me know your thoughts!!!

Paul G.

 

Sorry to hear about your problem! Looks like they are taking care of it. Really appreciate your taking the time to document with pictures and educate/inform the rest of us about it!

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chuckw
red '00

 

No problemo Chuck! It's a reciprocal thing around here and it's feels good to give back once in a while. Keep your eye on that resevoir because I also heard that you 2000 gent.s have the same part.

I gather you are having fun with your Bolt?!!!!

Paul G.

 

Excellent work. I personally had no idea of the exact setup that Ford used. I'm sure that this information will help all of us sometime in the future. Thanks for taking the time to gather the info.


99 EX-COBRA OWNER
Y2K WHITE L

 

Nice job PBGas!
If you don't mind I would like to put your photos at the Zing Lightning site. Again, nice job Paul.

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BABolt
SVT#290

 

Please send both part numbers if you can. If I can verify what you say is true. I'll start a class action lawsuit against them this week. They ordered a "new" intercooler and plugs, for mine today. Give me both part numbers HOW DO YOU KNOW THE SECOND NUMBER IS AN UPDATED VERSION???? This is the key question.
noelvm

 

Looking at these pics it makes me wonder how these trucks even breath.Imagine the power af this truck without all that restriction! I know its good to keep it cool but Damn ,It looks like there is some good power to make with a diffent intercooler

 

Thanks for the look-see at the culprit. i'd imagine our boost gauges are reading boost b4 that major "clog". that thing has to be good for 2-3 psi of reduction of real boost. "when" mine craps out beyond warrenty (36k), what are the possibilities of gutting it, and running a unrestricted water spray? is it a mechanical system or are there computer controls involved.

 

Dammit - last I heard was that intercoolers in March were going to be the new ones. I was all excited that my new engine had a 4-12-00 date code. So much for that theory!

Oh well, just have to keep an eye on that little jug o' green.

Thanks PB for the extra effort on this one.

Just curious, ever have any problems not running a front licence plate on your L here in Ontario? At least I'll know who it is when I see you!

As a final thought to comments about the intercooler restriction, try to imagine the area of the venturis of a holley four barrel. I think we have that covered by a long shot. Also, the area of our blower inlet is actually the restriction, not the intercooler. Just my $0.02 .