TSB 02-2-2
Publication Date: JANUARY 17, 2002

Coolant
Coolant seepage at intake manifold cross-over - Vehicles equipped with 4.6L 2V Engine Only
Engine
4.6L 2V - Coolant Seepage at Intake Manifold Cross-Over


FORD:
1996-97 THUNDERBIRD
1996-2001 CROWN VICTORIA, MUSTANG
  2002 EXPLORER
LINCOLN:
1996-2001 TOWN CAR
MERCURY:
1996-97 COUGAR
1996-2001 GRAND MARQUIS

ISSUE:

Some vehicles may exhibit an Intake Manifold crossover (first runner) coolant seepage condition. This may be caused by a crack in the Intake Manifold coolant crossover.

ACTION:

Inspect the suspect Intake Manifold for a coolant leak at the first runner cross-over area (Figure 1). If coolant seepage is found in this area, order the appropriate Service Kit and install parts, by referring to the appropriate Model Year Workshop Manual (Section 303-01).

4.6L 2V INTAKE MANIFOLD INSPECTION/REPLACEMENT

Refer to Figure 1 for inspection of coolant seepage. If seepage is found, order one of the following Service Kits to repair.

1998-2000 - Police/Limo - Crown Victoria, Grand Marquis, Town Car - KIT- F8AZ-9424-CA
Part Number Description Quantity
F8AZ-9424-CB Intake Manifold 1
F8AZ-10153-GA Alternator Brace 1
N806178-S309 Water Outlet Connection Bolts 2
XW7Z-9439-AA Intake Manifold Gasket 2
F1VY-8255-AA O-Ring For Thermostat 1
XW13-8B274-AA Upper Radiator Hose 1
1W7Z-8592-AA Water Outlet Connector 1
F8AZ-6A946-CA Engine Cover 1
N808455-S100 Nut 1
W705310-S309 Stud 1
SK 1W7E-9E473-BA Instruction Sheet 1


2002 Explorer - KIT- 1L2Z-9424-AA
Part Number Description Quantity
1L2Z-9424-FA Intake Manifold 1
1L2Z-10153-DA Alternator Brace 1
W708309-S437 Water Outlet Connection Bolts 2
YL3Z-9439-BA Intake Manifold Gasket 2
F1VY-8255-AA O-Ring For Thermostat 1
SK 1W7E-9E473-BA Instruction Sheet 1


1999-2001 Mustang - KIT- 1R3Z-9424-AAA
Part Number Description Quantity
1W7Z-9424-AA Intake Manifold 1
1R3Z-10153-AA Alternator Brace 1
W708309-S437 Water Outlet Connection Bolts 2
YL3Z-9439-BA Intake Manifold Gasket 2
F1VY-8255-AA O-Ring For Thermostat 1
2R33-12B637-AD Wiring Harness 1
SK 1W7E-9E473-BA Instruction Sheet 1


1996-1998 Mustang, 1996-1997 Thunderbird, Cougar - KIT- F6SZ-9424-AA
Part Number Description Quantity
F8AZ-9424-CB Intake Manifold 1
F8AZ-10153-EA Alternator Brace 1
W708309-S437 Water Outlet Connection Bolts 2
XW7Z-9439-AA Intake Manifold Gasket 2
F1VY-8255-AA O-Ring For Thermostat 1
XL1U-10329-BA Alternator Insulator (10.6 N-m (93 Lb-in.) Nut torque) 1
SK 1W7E-9E473-BA Instruction Sheet 1


2001 - Retail - Crown Victoria, Grand Marquis, Town Car - KIT- 1W7Z-9424-AAA
Part Number Description Quantity
1W7Z-9424-AA Intake Manifold 1
1W7Z-10153-CA Alternator Brace 1
W708309-S437 Water Outlet Connection Bolts 2
YL3Z-9439-BA Intake Manifold Gasket 2
F1VY-8255-AA O-Ring For Thermostat 1
SK 1W7E-9E473-BA Instruction Sheet 1


1998-2000 - Retail - Crown Victoria, Grand Marquis, Town Car - KIT- F8AZ-9424-BAA
Part Number Description Quantity
F8AZ-9424-CB Intake Manifold 1
F8AZ-10153-FA Alternator Brace 1
N806178-S309 Water Outlet Connection Bolts 2
XW7Z-9439-AA Intake Manifold Gasket 2
F1VY-8255-AA O-Ring For Thermostat 1
XW13-8B274-AA Upper Radiator Hose 1
1W7Z-8592-AA Water Outlet Connector 1
F8AZ-6A946-CA Engine Cover 1
N808455-S100 Nut 1
W705310-S309 Stud 1
SK 1W7E-9E473-BA Instruction Sheet 1


1996-1997 Crown Victoria, Grand Marquis, Town Car - KIT- F8AZ-9424-AAA
Part Number Description Quantity
F8AZ-9424-CB Intake Manifold 1
F8AZ-10153-EA Alternator Brace 1
W708309-S437 Water Outlet Connection Bolts 2
XW7Z-9439-AA Intake Manifold Gasket 2
F1VY-8255-AA O-Ring For Thermostat 1
SK 1W7E-9E473-BA Instruction Sheet 1


2001 - Police/Limo - Crown Victoria, Grand Marquis, Town Car - KIT- 1W7Z-9424-BA
Part Number Description Quantity
1W7Z-9424-AA Intake Manifold 1
1W7Z-10153-DA Alternator Brace 1
W708309-S437 Water Outlet Connection Bolts 2
YL3Z-9439-BA Intake Manifold Gasket 2
F1VY-8255-AA O-Ring For Thermostat 1
SK 1W7E-9E473-BA Instruction Sheet 1


PART NUMBER PART NAME
F8AZ-9424-CA Service Kit - Intake Manifold
1L2Z-9424-AA Service Kit - Intake Manifold
1R3Z-9424-AAA Service Kit - Intake Manifold
F6SZ-9424-AA Service Kit - Intake Manifold
1W7Z-9424-AAA Service Kit - Intake Manifold
F8AZ-9424-BAA Service Kit - Intake Manifold
F8AZ-9424-AAA Service Kit - Intake Manifold
1W7Z-9424-BA Service Kit - Intake Manifold

OTHER APPLICABLE ARTICLES:

NONE

WARRANTY STATUS:

INFORMATION ONLY

OASIS CODES:

402000, 499000




Figure 1 - Article 02-2-2