Fixed the coolant leak today, pics

bryanjw82 · 02-08-2006, 04:16 PM

Fixed my leak with new o-ring from Mc Master

begining the fix

coolant that was dripping onto the ground before fix

picture of tranny soaked with coolant because of leak

old o-ring that came out with the plug, see how its all worn out and has a square shape to it?

This is the new Mc Master Viton o-ring i ordered #203 installed on the plug

After installing the plug back with the new o-ring, the leak was over! This o-ring will take alot of persausion to get in but it will withstand the temperatures that the oem wouldn't. I have like 24 more of them, from a pack of 25. Ill part 15 or so of them if anyone needs this o-ring for a leak problem. Just let me know

***whynotthinkwhynot*** · 02-08-2006, 05:11 PM

I think the O ring was originally round shaped.. but over time heating and cooling made it mold to the shape of the space it was filling.

GOOD deal... I hope Duratecs don't have problems like this!!

roy-mikesvt · 02-08-2006, 08:13 PM

I will def. need one pretty soon..I've been really careful of watching my coolant levels..Will I need any other Items , other then what you have..I need to stop being lazy , hehe..How much you asking for?

Another thing..noob question..How do u pop that sucker out? And put the new one in..

JohnMichael · 02-08-2006, 08:42 PM

lol, judy did the same thing a few weeks ago...here's a few pics from mine:

Here was the leak spot...

Here was the new o-ring attached...took a bit of fab work getting it back in, I actually had to shave a bit off to get it to fit.

Hillyard · 02-08-2006, 09:41 PM

i had to shave quite a bit off my Viton o-ring too..it was bending the housing.

bryanjw82 · 02-09-2006, 10:21 AM

i didn't shave any of it off, i greased it up with gunk, and smacked it in with a hammer. I had to use a long bold to hold against the plug to reach it because there isnt' much space under there and then i smacked the back side of the bolt a few times and it was in.

Travis · 02-09-2006, 10:36 AM

Mine has been leaking for a while but I have ben lazy about it. I have topped off the coolant a few times and that is about it. does it just pop out? It doesn't seem to have any threads...And also do you lose much coolant when you take it out??

thanks

Also for the reinstall I am going to use silicone compound (dieltric grease; not RTV) because it won't deteriorate the rubber.

***viney266*** · 02-09-2006, 01:51 PM

Mine hasn't leaked yet( hope it doesn't ), .. What is that plug out of, I can't quite see the picture well enough.

JohnMichael · 02-09-2006, 05:43 PM

It's out of the thermostat housing...let's see if I can get some better pics up.

That's a top shot of the thermo housing, it's underneath towards the front of the housing...

The above pic is of the hole where the plug goes and housing...if you need some more shots just yell!

JohnMichael · 02-09-2006, 08:45 PM

The last pic I posted shows the exact location of the aluminum plug, you can see the coilpack directly above the plug in the pic as well as the hole where the plug fits...here's a pic of the little bitty clip that holds the plug in, and it SUCKS trying to get that little bastage back in. I had to use the opposite end of a hammer to ram the plug back in, and then hold it there with all my might as I tried to fit the little clip back in...

S2 · 11-23-2006, 03:03 PM

Added to the 'How To' Archive......

goinloco1 · 11-23-2006, 09:25 PM

if i recall correctly only the svtf has the plug.
of course my plug leaked, fixed that, then the housing cracked awhile later. ordered a new housing, the wrong one was sent. the plug hole was molded shut and so was the top sensor hole. i modified it and drilled the top sensor hole and used a coping saw to cut the grooves for the sensors keeper. no more worrying about the plug leaking! altho the sensor was a pita, the old oring fit loose, but a new one went in snug. i can get the housings part number if anyone wants and do a writup on how to mod it.

02-08-2006, 04:16 PM	#1
bryanjw82 Focus Addict Join Date: Aug 2003 Fan#: 222 Location: Sanford, Florida What I Drive: 2004 Chevy Avalanche Posts: 844 FF Reputation: 1 Buy-Sell-Trade Rating: (3)	Fixed the coolant leak today, pics Fixed my leak with new o-ring from Mc Master begining the fix coolant that was dripping onto the ground before fix picture of tranny soaked with coolant because of leak old o-ring that came out with the plug, see how its all worn out and has a square shape to it? This is the new Mc Master Viton o-ring i ordered #203 installed on the plug After installing the plug back with the new o-ring, the leak was over! This o-ring will take alot of persausion to get in but it will withstand the temperatures that the oem wouldn't. I have like 24 more of them, from a pack of 25. Ill part 15 or so of them if anyone needs this o-ring for a leak problem. Just let me know __________________ Performance Mods: FC short shifter, Magnaflow exhaust, HEI wrapped svt header, BBK TB, orp, MSD coil & wires, Diablo Tuner, VF engineering rear engine mount, EBC slotted and dimpled rotors f&r, EBC green stuff pads, PowerWorks Supercharged

02-08-2006, 08:42 PM	#4
JohnMichael Michael J. Caboose Join Date: Apr 2005 Fan#: 21469 Location: Hammond, LA What I Drive: Black Hemi Ram & Honda Shadow VT600 Posts: 6,526 FF Reputation: 7 Buy-Sell-Trade Rating: (5)	lol, judy did the same thing a few weeks ago...here's a few pics from mine: Here was the leak spot... Here was the new o-ring attached...took a bit of fab work getting it back in, I actually had to shave a bit off to get it to fit. __________________ Cap America and Deadpool walk into a bar, Cap orders a glass of milk, because he's Cap. DP orders a glass of Human Crap, because he's Deadpool. O'er Pirates from the Black of Pitch

02-08-2006, 09:41 PM	#5
Hillyard Supercharged Join Date: Jul 2004 Fan#: 10982 Location: Evansville, IN, United States What I Drive: 2002 ZX3 SVT, 2004 Ford Ranger 4x4 Posts: 3,264 FF Reputation: 2 Buy-Sell-Trade Rating: (27)	i had to shave quite a bit off my Viton o-ring too..it was bending the housing. __________________ #3788 InfraRed SVT Hill <><

02-09-2006, 10:21 AM	#6
bryanjw82 Focus Addict Join Date: Aug 2003 Fan#: 222 Location: Sanford, Florida What I Drive: 2004 Chevy Avalanche Posts: 844 FF Reputation: 1 Buy-Sell-Trade Rating: (3)	i didn't shave any of it off, i greased it up with gunk, and smacked it in with a hammer. I had to use a long bold to hold against the plug to reach it because there isnt' much space under there and then i smacked the back side of the bolt a few times and it was in. __________________ Performance Mods: FC short shifter, Magnaflow exhaust, HEI wrapped svt header, BBK TB, orp, MSD coil & wires, Diablo Tuner, VF engineering rear engine mount, EBC slotted and dimpled rotors f&r, EBC green stuff pads, PowerWorks Supercharged

02-09-2006, 01:51 PM	#8
*viney266* Moderator Join Date: Jun 2003 Fan#: 93 Location: westminster, maryland, MD What I Drive: focus ztw ,zx3,mustang, motorcycles Posts: 22,673 FF Reputation: 103 Buy-Sell-Trade Rating: (3)	Mine hasn't leaked yet( hope it doesn't ), .. What is that plug out of, I can't quite see the picture well enough. __________________ Speed is only a matter of money; how fast do you want to go? Ninja Mod

02-08-2006, 05:11 PM	#2
*whynotthinkwhynot* Captain TMI Join Date: Jan 2005 Fan#: 18416 Location: the armpit of TN, Memphis, TN What I Drive: 05 ZXW; 2002 Land Yacht (Windstar) Posts: 10,770 FF Reputation: 213 Buy-Sell-Trade Rating: (0)	I think the O ring was originally round shaped.. but over time heating and cooling made it mold to the shape of the space it was filling. GOOD deal... I hope Duratecs don't have problems like this!! __________________ ---The Complete How-To Archive-- Moderating Tech Chat and Duratec Chat, let me know if I can help.

02-08-2006, 08:13 PM	#3
roy-mikesvt Focus Enthusiast Join Date: Feb 2004 Fan#: 4225 Location: dallas tx What I Drive: 05 Mazdaspeed Miata Posts: 288 FF Reputation: 1 Buy-Sell-Trade Rating: (0)	I will def. need one pretty soon..I've been really careful of watching my coolant levels..Will I need any other Items , other then what you have..I need to stop being lazy , hehe..How much you asking for? Another thing..noob question..How do u pop that sucker out? And put the new one in..

02-09-2006, 10:36 AM	#7
Travis Focus Enthusiast Join Date: Nov 2003 Fan#: 1664 Location: Chula Vista, CA What I Drive: 2002 SVT Focus Posts: 66 FF Reputation: 1 Buy-Sell-Trade Rating: (0)	Mine has been leaking for a while but I have ben lazy about it. I have topped off the coolant a few times and that is about it. does it just pop out? It doesn't seem to have any threads...And also do you lose much coolant when you take it out?? thanks Also for the reinstall I am going to use silicone compound (dieltric grease; not RTV) because it won't deteriorate the rubber.

02-09-2006, 05:43 PM	#9
JohnMichael Michael J. Caboose Join Date: Apr 2005 Fan#: 21469 Location: Hammond, LA What I Drive: Black Hemi Ram & Honda Shadow VT600 Posts: 6,526 FF Reputation: 7 Buy-Sell-Trade Rating: (5)	It's out of the thermostat housing...let's see if I can get some better pics up. That's a top shot of the thermo housing, it's underneath towards the front of the housing... The above pic is of the hole where the plug goes and housing...if you need some more shots just yell! __________________ Cap America and Deadpool walk into a bar, Cap orders a glass of milk, because he's Cap. DP orders a glass of Human Crap, because he's Deadpool. O'er Pirates from the Black of Pitch Last edited by JohnMichael; 02-09-2006 at 08:42 PM.

02-09-2006, 08:45 PM	#10
JohnMichael Michael J. Caboose Join Date: Apr 2005 Fan#: 21469 Location: Hammond, LA What I Drive: Black Hemi Ram & Honda Shadow VT600 Posts: 6,526 FF Reputation: 7 Buy-Sell-Trade Rating: (5)	The last pic I posted shows the exact location of the aluminum plug, you can see the coilpack directly above the plug in the pic as well as the hole where the plug fits...here's a pic of the little bitty clip that holds the plug in, and it SUCKS trying to get that little bastage back in. I had to use the opposite end of a hammer to ram the plug back in, and then hold it there with all my might as I tried to fit the little clip back in... __________________ Cap America and Deadpool walk into a bar, Cap orders a glass of milk, because he's Cap. DP orders a glass of Human Crap, because he's Deadpool. O'er Pirates from the Black of Pitch

11-23-2006, 03:03 PM	#11
S2 Retired Fanatic Join Date: Mar 2004 Fan#: 4939 Location: Canada, Afghanistan What I Drive: 2005 RSX-S, 2006 S40 2.4i Posts: 20,029 FF Reputation: 68 Buy-Sell-Trade Rating: (20)	Added to the 'How To' Archive...... __________________ Chad (S2)

11-23-2006, 09:25 PM	#12
goinloco1 Focus Fanatic Join Date: May 2004 Fan#: 8529 Posts: 13,826 FF Reputation: 81 Buy-Sell-Trade Rating: (1)	if i recall correctly only the svtf has the plug. of course my plug leaked, fixed that, then the housing cracked awhile later. ordered a new housing, the wrong one was sent. the plug hole was molded shut and so was the top sensor hole. i modified it and drilled the top sensor hole and used a coping saw to cut the grooves for the sensors keeper. no more worrying about the plug leaking! altho the sensor was a pita, the old oring fit loose, but a new one went in snug. i can get the housings part number if anyone wants and do a writup on how to mod it.

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