jkenprice1

I'm not sure what you're seeing. There are coolant passages at the 4 corners of the intake manifold. One is directly below the thermostat.

Baker

Thanks jkenprice1. That's my question, "is there a gasket where the manifold coolant passages are?" If there is, then I doubt the JB Weld will do anything and the manifold will have to be removed and the gaskets replaced. That gasket/seam area is about 2" below the thermostat gasket.

jkenprice1

That's right. I haven't had my 97 for about 5 years, but I still have the Haynes manuel. You should get one. Good info and lots of pics. There is a gasket, and it would be great if that's the extent of the problem.

Baker

Any chance that something like Barr's Stop Leak will fix it? I know most everybody is rolling in laughter. I've never had anything from a can fix any engine problems but it has been years so maybe a miracle fix is out there. Thanks.....

jkenprice1

I don't know. Iv'e never used stuff like that. I know that would be easy, but it wouldn't really fix the problem. I've always been afraid it would clog up other stuff.

Baker

Same fear here. Just hopin'. thanks...

jkenprice1

That should be a fairly simple job. Just look at it as bonding time!

Baker

I finally located the leak and it is in the cylinder head below the thermostat housing, not the manifold gasket. After 2 coats of JB Weld and almost a week of cure time ( temps have been 20's to 50's ) with the aid of a drop light. Fired up the truck today and there are no leaks. Installed new thermostat while I was in there but I do now have "Check Engine" light on. Probably messed up a sensor somewhere. Will schedule a coolant flush shortly. Thanks to all who helped.

Mr. Beef Gravy

A flush might push the jb out of your repair. The check engine light is not a result of bad coolant. It's most likely a sensor that got wet from the leaking. I would have it reset after everything dries out.

As far as the casting, I have only heard of a few issues like this but they were with the casting on the 32v 4.6 and I checked the Ford service bulletins and there isn't anything. Unless your coolant is due such as time or miles, I would leave it until you have run this repair in.

BossRacing71

+1......also, make sure you reconnected any and all wires you unplugged during your adventure. The "check engine" will show if any wires are loose or disconnected.