Coolant leak....... D@mn/t!!!!

Well tonight I found out where the coolant has been leaking from my car. Apparently the nipple on the intake manifold that the heater hose attaches to broke in half at an angle and now the hose doesn't make a good seal. From what I have read, it is one molded piece and I will have to replace the entire manifold. Is this true? If so, can anyone recommend a good one that won't cost me an arm and a leg. I also need to find the part local so I can get this repaired as soon as possible so I can get back to work. Thanks for any suggestions.

From what I remember my 96 car had a replacement manifold because the plastic crossover piece cracked. The replacement had metal crossovers. Is this the part you are talking about? If so I think you have no other alternative other than an aftermarket piece or the ford one with metal crossovers.

Might be able to tap a new nipple on there I'd have to see it?

Im with David on this. My mothers 96GT cracked her upper plenum

This is the part that is broken. It broke at an angle all the way down to the base where there is a lip to keep the hose from pushing farther on.

Wow, that sucks. The common cracking area is on the other end in the crossover. Unfortunately I think you'll have to replace it. You might be able to find one used at a salvage yard. Just have to call around. I doubt it is a part on the shelf at the local auto parts store.

looks like about $200 on Ebay.

i found this one for $50. Need some more research on this one. It has the plastic crossover coolant tube. http://cgi.ebay.com/ebaymotors/96-98-99-04-Mustang-GT-PI-Intake-Manifold-Cheap-/190472223583?pt=Motors_Car_Truck_Parts_Accessories&fits=Make%3AFord|Model%3AMustang&hash=item2c59077b5f

This one is used and a buy now for about $125. http://cgi.ebay.com/ebaymotors/Mustang-Ford-4-6-PI-intake-manifold-aluminum-crossover-/220697510414?pt=Motors_Car_Truck_Parts_Accessories&hash=item336298c20e

This one at $35 but it states that its not the "PI" manifold. http://cgi.ebay.com/ebaymotors/Mustang-GT-4-6-non-pi-intake-manifold-OEM-1994-2004-/190472694071?pt=Motors_Car_Truck_Parts_Accessories&fits=Make%3AFord|Model%3AMustang&hash=item2c590ea937

The PI manifold has the aluminum crossover. The other is plastic and prone to cracking. I still wonder if it might be possible to cut away the nipple and tap the remaining hole to receive a brass fitting?

DBLDARE wrote:The PI manifold has the aluminum crossover. The other is plastic and prone to cracking. I still wonder if it might be possible to cut away the nipple and tap the remaining hole to receive a brass fitting?

That was my thought. My father-in-law rebuilds alot of Mustangs so I am asking him for help. I've got a quick fix that will hopefully get me back on the road until I have the time to fix it correctly. If not I'm going to try to grind it smooth, tap the hole, and fit in a new nipple. Hopefully that will keep me going long enough to save up some extra money for a whole new manifold.

I may have missed it.... but what year? Obviously these have a long history of problems. A friend of mine had it replaced by Ford under a TSB several years back. Might be worth looking into.

2006GT wrote:I may have missed it.... but what year? Obviously these have a long history of problems. A friend of mine had it replaced by Ford under a TSB several years back. Might be worth looking into.

Its under his Avatar and name

I bet if you tap it and use some Teflon tape on the threads then put in a fitting commonly available at someplace like lowes or home depot you'll be fine. Might even be better than stock. Lol

An update to this story:

I tried about a week ago to use some silicone to adhere the hose to the broken fitting in an attempt to make a good seal. I let it sit for about a day and a half and fired it up. All good. Drove it for a few days and started thinking that everything was going to be fine. It wasn't. Driving down the B.A. I happened to look in my rear view mirror and it looked like I had released a smoke screen. I pulled off the highway at the 15th street exit and pulled in the nearest parking lot. Looked under the hood and the hose had blown loose and all my coolant had shot out in a big gush of steam.

I got my parents to use their truck and trailer to pick it up and haul it to their house since I was still at work. My step-dad is one of those guys that can fix anything and he called me a few hours later and said that he had fixed it. He ground the broken part off the manifold, tapped the hole, and fitted two pipe pieces together and plumbers taped them in there.

We tested it out and everything held up under full load, heater cranked all the way up and I drove it down the road so it would get the temp up. I've been driving it for about a week now and haven't had any problems.

I'll get some pictures up on here when I get a chance.

I bet it stays if the tap was good. At least long enough to get you through until you can get a new one.

thats good.

Glad it worked out for you.

Good to hear!