coolant hose at intake manifold

[daveak1958]

\i am in the process of changing the intake manifold gaskets on my 3.8 windstar and I am stuck at this hose comeing out the end of the manifold it has a plastic quick coupler on it and the pipe is rusted and I cnat seem to get it off and before I go crazy was wondering if anyone has a solution for me.
Thanks

[12Ounce]

You would be better off if you can save that quick-coupling ... there are repair kits out there, but the thin-walled steel tubing that comes out of the manifold can also break ... and that is tougher to repair.

I would recommend wrapping an oil soaked cloth around the fitting ... and massageing it ... trying to get some oil down in that coupling. And then continuing to work slowly with care.

[Jeff Collision]

Changing the lower intake Manifold Gasket is little hard. Try to clean the rust on the quick coupler pipe by specialized powders. Then, carefully clear the old gasket on the manifold and head. Clear the bolt and bolt hole in the head, then carefully install the lower intake Manifold Gasket. Check the coolant passage in order to avoid the coolant leaking.

[scubacat]

Some people just cut off that fitting and use a regular hose clamp with no problems. I was fortunately able to get it off by just pressing in the tabs with a screwdriver. (Odd how they call it a "quick connect" when it takes so much longer than all the regular hose clamps?!)

You can also buy a new fitting at a dealer if it breaks. It shouldn't cost too much, although I hate giving those people more money than I absolutely have to.

[wiswind]

What tends to break in the quick connect fitting is the nylon tabs part.
They get brittle from years of exposure to heat cycles and oil, etc.
The repair kit gives you a new nylon "tab" part and lets you use the same black connector body.


It is critical to get all the "O" rings, spacer and nylon tab part in place and the connector clipped in place on the "flange" on the pipe.
THIS picture shows these parts in place without the black body of the connector blocking your view.
The purpose of this picture is to show the proper placement of these parts.

Looking at the picture....the nylon "clip" part has tabs that stick out....when you press a tab in....the tab is opposite that tab...that points INTO the pipe will flex out. Pushing INWARD on the hose/quick connect body will tend to make the in-pointing tab release much easier.
If you are trying to pull the hose off....it will tend to make the in-pointing tab stick.......and breakage is more likely.
I would recommend buying a NEW "clip" part (repair kit) so that you have a more flexible, less likely to break part.
ALSO.....you need to press inward on BOTH of those outward pointing tabs at the same time, while pressing inward slightly on the hose/connector body.....then, with both tabs pressed in....pull the hose/connector body out, away from the engine.

There is a tool that you can borrow/buy from local auto part stores that you slip over the tabs....that presses them in for you.
Kind of looks like a little crowbar (but it is not).

That metal pipe is press fit into the lower intake manifold.
I do NOT know the process for replacing the metal pipe as I was lucky enough to not have to face that job......and would not want to be faced with that.

[kevink1955]

I just cut the quick connect off and put the hose back in the steel pipe with a regular hose clamp, It's been that way for 50,000 miles with no problem. Just got reminded that I did it last weekend when I pulled the upper intake to clean the EGR ports

[LTDzak]

I got mine off, with the metal tube left intact, by very carefully dremeling the inner plastic clip, both sides, through each "window", where the clip edges seat on the baclk plastic portion (having the "windows"). Afterwards I found the hose no longer avialable from Ford, and had to buy the hose, and the quick connect adapter separately. For the quick connect, get the largest 3/4 inch one, IIRC only Advance Auto had it.

Should mention that you're not trying to drmel those tabs off completely, just reduce the amount that they stick out so that you can squeeze the tabs qand get it to release.

[catvents]

Originally Posted by LTDzak

I got mine off, with the metal tube left intact, by very carefully dremeling the inner plastic clip, both sides, through each "window", where the clip edges seat on the baclk plastic portion (having the "windows"). Afterwards I found the hose no longer avialable from Ford, and had to buy the hose, and the quick connect adapter separately. For the quick connect, get the largest 3/4 inch one, IIRC only Advance Auto had it.

Should mention that you're not trying to drmel those tabs off completely, just reduce the amount that they stick out so that you can squeeze the tabs qand get it to release.

Yes Advance has it in his cooling counter section, just seen yesterday. For the information of everybody, it's also available online from Rock Auto (just scroll to " Heat/Air conditionning" section then see "Heater hose connector"
3/4 in is $7.32 (similar price at Advance). Mine was broken, I have gently breaked and removed the remaining of the connector, cut the hose before the crimping metal clamp then install new connector and connected hose on it. Metal tube out of the manifold was rusted so I have paid attention for not breaking it. And yes the shortest way is to connect the hose directly on the tube without the connector.