Cooling System/A/C - Heater Hose Leaks
TSB 05-25-312/26/05
COOLANT LEAK - HEATER HOSE CONNECTIONS
FORD:
2006 Explorer
MERCURY:
2006 Mountaineer
ISSUE
Some 2006 Explorer and Mountaineer vehicles may experience a coolant leak at the heater hose supply line connection at the engine on 4.6L equipped vehicles or a coolant leak at the heater core connections on both 4.0L and 4.6L equipped vehicles, which may leak onto the passenger side carpet.
ACTION
Install a secondary clamp or replace the existing clamp, depending on the leak location.
SERVICE PROCEDURE
1. Determine the coolant leak location by following the procedures listed in the Workshop Manual Section 303-03 (Pressure Testing The Cooling System). Proceed to Step 2.
2. If the leak is determined to be at the heater hose supply connection to the engine (4.6L engines only) (refer to Figure 1), proceed to Step 3. If the leak is determined to be at the heater hose to core connections (all engine applications) (refer to Figure 2), proceed to Step 6. If the leak is determined to be at any other location, do not continue with this TSB and follow normal service/repair procedures.
3. Add a secondary worm gear clamp W709811-S900 to the hose connection.
NOTE
THIS WILL REQUIRE REMOVAL OF THE AIR INTAKE TUBE.
NOTE
THE PREFERRED LOCATION IS IMMEDIATELY BEHIND (AWAY FROM THE ENGINE) THE CLAMP THAT IS PRESENT ON THE HOSE. IN SOME CASES, THERE MAY NOT BE SUFFICIENT LAND AREA ON THE ENGINE PORT BEHIND THE EXISTING CLAMP. IN THAT CASE IT IS PERMISSIBLE TO INSTALL THE SECONDARY CLAMP ON THE OTHER SIDE OF THE EXISTING CLAMP.
4. Tighten the worm gear clamp to 27 lb-in (+/- 4 lb-in) or 3 N.m (+/- 0.4 N.m).
5. Verify that coolant is not leaking at the connection point. Proceed to Step 6 only if necessary.
6. Relieve system pressure as outlined in the Workshop Manual, Section 303-03.
7. Drain the cooling system.
8. Remove the retainer for the heater tube to bulkhead bracket.
9. Disconnect both heater hoses to heater core connections.
10. Remove the hose clamp at heater core by using a heat gun to release the glue that locates the clamp on the rubber hose, or by cutting the glue bead.
NOTE
USE CAUTION SO AS NOT TO CUT INTO THE RUBBER OF THE HOSE. IF DAMAGE TO THE HOSE OCCURS REPLACE THE HOSE.
11. Install a worm gear clamp (12.5 mm band width, part number: 389772-S100) around heater core hose at the same location as the hose clamp.
12. Connect both heater hoses to heater core connections.
13. Tighten worm clamps to 30 lb-in (+/- 3 lb-in) or 3.4 N.m (+/- 0.34 N.m).
14. Install the retainer for the heater tube to bulkhead.
15. Fill the cooling system as outlined in the Workshop Manual, Section 303-03.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052503A 2006 Explorer/Mountaineer 0.5 Hr.
4.6L: Pressure Test
Cooling System, Install
Secondary Worm Clamp,
Pressure Test Cooling
System To Verify Repair
(Do Not Use With 8005D
8100A, 18472A)
052503B 2006 Explorer/Mountaineer 1.0 Hr.
4.6L Pressure Test Cooling
System, Install Worm Type
Clamps On The Heater
Hose To Heater Core
Connection (Do Not Use
With 8005D, 8100A,
18472A)
052503C 2006 Explorer/Mountaineer 1.1 Hrs.
4.6L Pressure Test Cooling
System, Install Secondary
Worm Clamp, Pressure
Test To Verify Repair,
Install Worm Type Clamps
On The Heater Hose To
Heater Core Connection
(Do Not Use With 8005D,
8100A, 18472A)
052503D 2006 Explorer/Mountaineer 1.0 Hr.
4.0L SOHC Install Worm
Type Clamps Heater Hose
To Core Connection
Includes Time To Remove
Spring Type Clamp From
Heater Hose To Heater
Core Connection (Do Not
Use With 8005D, 8100A,
18472A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
18C266 33
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