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2001 Windstar Coolant hose pipe leak Solved with Pictures

12-18-2007, 08:43 PM
I've discovered the coolant crossover pipe on the 3.8 that runs under the Intake manifold has a defect that will cause it to leak at a given point (after warranty). My pipe looked brand new but had a pinhole leak that would have never been found had I not run the engine and luckily saw a small stream coming out from under the upper intake plenum.

The other pipe that this connects to which tees off into the water pump and to the firewall hoses sprung a similar leak exactly one month later.

The pipe with the yellow tape is the new replacement. $30 bucks, $60 for the one under the intake! Beware, this one has a bolt on the rear of the PS pump and connects to a firewall heater hose T and to the hose that runs under the Intake. I wish I would have known about this problem when I replaced the Isolator bolts about a year ago.

Picture can be seen at following link: Pinhole leak:

Location of other pipe: Pipe has yellow sticker attached

This is a picture of the pipe that runs under the intake, the shiny new one in the center of the pic:

I plan to put a case together and present it to FORD to show that the pipes are in like new condition and that the leak obviously (from reading other message boards) is caused by a defect in Manufacturing. I plan to get my $$ back for their negligence. Who's In!


12-18-2007, 08:46 PM
thanks for trying: I get dead links on the pictures.

northern piper
12-19-2007, 08:08 AM
linky no worky

02-29-2008, 03:02 PM
Sorry about the bad links, I replaced them below on my post

03-01-2008, 01:54 PM
Sorry about the bad links, I replaced them below on my post
GOOD PICS... I have a 2001.. oh by the way its time for us 2001 owners to start changing radiator hoses if you have not yet.. 7yrs its time.

03-01-2008, 03:31 PM
daveck2, was the tube that is inserted into the top of the water pump seized? When I pulled mine to do the synchroziner replacement, it took
me an hour to bust it loose. As you mentioned there is also an attachment point at the power steering pump (Haynes does not mention that). I worked
the tube back and forth and even used a slide hammer on it, I'll have to apply some paint or sealant where the paint was chipped off.

03-07-2008, 10:56 AM
"was the tube that is inserted into the top of the water pump seized?"

No, it came out fairly easy once I got the rear bolt off.

03-07-2008, 01:21 PM
I did the isolator bolt repair last year. If I go ahead and replace this coolant pipe as a preventative, would I have to get new gaskets for the intake ports?

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