Hey guys (and gals),

Guess what? Ford dealer called me today, my beast is currently in the shop getting it's heart swapped out. Service manager said that they got everthing back together, started the new engine, and it developed a coolant leak in the intake manifold (gasket). Now they had to pull the intake off, and are currently scouring this region of the country for a new intake manifold gasket. They said the the current gasket was gouged, probably during assembly on the line.

So, I'm still "toot'in" around in the loaner (Escort), waiting for the engine swap to come to a conclusion. Just goes to show you (Fordman) that more than ever, an ESP looks better and better every day...If I can't even get a good engine off of the manufacturing line, I'd hate to think what could happen later with the currently installed parts on my truck. You see now, I hope, that an ESP is proper and warranted on these trucks for later problems that are likely to develop, although I'm am actually an optimist about the Ford product...

-Just stuck that last comment in there for sh*ts and giggles, me and Fordman have been going round 'n round in the "Tips and Tricks" section about the Ford ESP....

-kindest regards

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1999 F150 4x4, wedgewood blue, 5.4l auto, Manick brush guard, Duraliner, KC Hilites, surf rod holders, tinted windows, K&N air filter without airbox, Gibson side swept exhaust, toolbox, Uniden CB with whip, and now, currently under anethesia at Academy Ford in Laurel, Maryland, undergoing a heart transplant (to replace a Piston Slapp'in Engine)...

 

Sounds to me like your dealer is giving you a load of bull. The intake is reused, therefore it would be a pretty good assumption that they screwed up the gasket while performing the replacement. It's pretty unlikely that the factory gouged the gasket. If that was the case, the dealer shouldn't have used it when installing the intake. Juz my .02

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99 XLT Black Ex-cab, Flareside, 5.4, ORP, 3.73, Gibson Supertruck, K&N, Superchip, Raised front 1", Modified Airbox, Slap-Free Motor at @19k

 

The new engine that I recieved from Ford is complete with the new plastic type intake manifold, no parts are reused or remounted other than the compressor, altenator, etc. I inspected the replacement before they installed it, it was complete with exhaust and intake manifolds, heads, valve covers and flywheel...

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1999 F150 4x4, wedgewood blue, 5.4l auto, Manick brush guard, Duraliner, KC Hilites, surf rod holders, tinted windows, K&N air filter without airbox, Gibson side swept exhaust, toolbox, Uniden CB with whip, and now, currently under anethesia at Academy Ford in Laurel, Maryland, undergoing a heart transplant (to replace a Piston Slapp'in Engine)...

 

If I understand the 97/98 vs 99+ FQR engines correctly, you get a Quality Renewal stickered engine for 97/98's (with no intake manifold and various other things which are reused from old engine), while 99+ get new engines - complete. I think that's how it works. My 98 F-250 5.4 came w/o manifold, etc. I hear a 'gurgling sound' sometimes (from the front right dash area) along with rough idle/smoke/quiet desiel sounds. Will have it in for check up next week.

 

BTW, the smoke seems a lot like heavy dew, like foggy smoke - kinka reminesent of a blown head gasket like smoke. Almost thick. Definitely not you normal morning hot to cold air mist/fog on startup.
Frank

 

When updating the "FQR Updates" post, I mentioned a similar coolant mystery. My FQR seems to have lost some coolant over a 3 week period. Very strange. Go read it there.

Frank