windstar 96 extensive external coolant leak

[mikemf]

Recently my windstar 96 got overheated. I replaced thermostat. It was OK for a month. Then, it overheated again. (What was strange that both times coolant tank was full) Now when I try to put water into radiator, it extensively leaks somewhere below thermostat (I can't fill radiator). It's neither the hose nor thermostat connection leak. It seems that it leaks below the place where top of transmission is connected to the engine. Van starts. No oil in coolant. No coolant in oil. No white smoke. What can it be? If gasket, what gasket?
Thanks.

[DRW1000]

I assume you can see it on the ground. You mentioned that THE hose is okay. Which hose are you referring? There is an upper and lower rad hose. There will be heater core hoses. If you have read HVAC there will be lines to the rear heater core running under the van. There are also sand cast plugs (often referred to as frost plugs) they can rust. The rad can also leak. You could also have a head gasket leaking from the water jacket to outside and if the head gasket is bad this is probably the best scenario. IE no water in the oil or cylinders.

You may need to drive it up on car ramps and watch from underneath as a helper fills.

Of course non of this answers the question as to why it overheated. One question:

If it was full when it over heated why were you filling it? I only ask to understand. Sounds like it lost coolant and then overheated. I think step one is to find the leak.

[mikemf]

Thanks for reply.
Yes, it got overheated because it lost coolant. But I didn’t see any leakage prior to that and car was running fine. Also why the coolant in the tank was not sucked into radiator when it was overheated? I checked small hose from tank to radiator and it is fine.
I'm referring to the upper hose that goes from radiator top to thermostat. Leak is very extensive (it's pouring; no way to fill radiator and try to run). Can such extensive leak be from blown gasket? It leaks from engine body (or gasket or cast plug) right below the place where transmission is bolted to engine (right below the upper bolt, so it's not possible to see from top). From below (when I removed starter and small cover) I can see that leak is above crankshaft wheel. I also talked to a Ford service man. He was very sure that the cause is a rusted sand cast plug. He said there are six of them in that engine and that they are just pressed / snapped into engine body (no bolts). What are those plugs for? Do you know their locations? It seems that I'll need to disconnect transmission from engine in order to get to the plug (place) that leaks. The Ford man also said that if it's indeed plug leak then I should better replace them all.
Thanks

[kok328]

Sounds like you could have either blown a freeze plug or blown the intake gasket.

[mikemf]

Just did some checking. Frost plugs are OK. I found six of them, and they are not leaking. Most likely it is gasket. The only confusing thing is that the leak is so extensive. When putting water in radiator, it leaks in continued stream (like from a small hose). Can a gasket leak be so extensive? Can it be a crack in the engine? I checked spark plugs as well. They are fine too.

[oluckyme]

I don't know if this will help but I just had a simmaler problem on my 2000
LONG story short the leak was from a steal tube that pressed into the top of the intake. Then ran under the intake plenuem to the passanger side of the motor to some flex hosses. The tube cracked up under the intake plenum. After a few hours of searching and assumeing that is was a intake gasket I found it. I had to break one of my wifes compacts and use the small mirror to see under the plenuem with the aid of a flash light I could barly see the leak. I did do the work my self and it wasent extremly dificult if you need to know more let me know. I owned two 95 windstars and know they were a littel diffrent set up but I belive that this is still possable. One month after this another tube split that ran to the back heater system. This one was easier to see. good luck

[mikemf]

Thanks ‘olukyme’. I already took air filter and some other parts away and I can clearly see the steal tube that you mentioned. It’s not leaking.
Today I went to a junk yard and looked for disassembled Ford engines. I didn’t find Windstar engine, but I found engines of ‘Taurus’ and other Fords. On all those engines on the side that connects to the transmission, there are at least two or three plugs. One bigger in the middle and two or one smaller (I think) frost plugs. All of them are covered by transmission body, so in order to check or change them I have to disconnect transmission from engine. Can somebody confirm that Windstar 96 engine has some plugs (frost or ??) that are covered by transmission body? Are those coolant plugs? I was told by A Ford man that there are six frost plugs. I found all of them in reachable places on engine. Does Windstar 96 have more than six frost plugs?