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Old 08-03-2015, 05:10 PM   #1
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Coolant Overflow Issue

Recently I had to replace the intake manifold on my 03 GT. I used the FRPP Intake Manifold (basically OEM), Ford Intake Gaskets, new thermostat (from Autozone), thermostat gasket, and a few other things that aren't related to the coolant system (New EGR Valve and Motorcraft spark plugs, for example).

I made sure to clean out the spark plug ports and wipe down the whole area as best as I could (made sure nothing fell into any ports as well), and after the first fire up, I realized I had to replace the radiator fan, so I bought one from Advanced Auto Parts. When I first plugged it in it wouldn't turn on, but after messing with the connection, it's been turning on and off as normal.

Since then, whenever I would stop (shut the car off, etc.) the radiator overflows and leaks out a puddle. I would refill it to the "Add Coolant" mark and it would do it again. I even tried filling up to well below the "Add Coolant" Mark and it would overflow (less than before, but overflow nevertheless). Eventually it'll stop doing it and the coolant in the reservoir appears to be near empty.

It's worth mentioning that during all this, my coolant gauge stays at the same level when warmed up and it hasn't actually overheated at all, even during the hot 90 degree plus summer in NJ. Any ideas as to what's causing this issue?


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Old 08-03-2015, 09:20 PM   #2
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After you completed the intake swap, did you try to remove the trapped air in the cooling system by "burping" it?
Another possibility is, your radiator cap may not be holding pressure like it should be, and might need to be replaced.
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Old 08-04-2015, 03:10 AM   #3
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I would say burp it and get a new cap like stray said then go from there.

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Old 08-26-2015, 03:22 PM   #4
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I just wanted to give an update on this scenario. I was finally able to work on the car (been busy) and I burped the system again. This time I used the correct funnel (finally got my hands on one). I also replaced the radiator cap and I'm happy to report the issue hasn't come back since. Also, I was having an intermittent miss under heavy throttle and now that has seen to go away as well. Strange, but everything seems to acting normal, so for now, I won't question anything. Consider it solved. Thanks everyone!
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