Windstar :: 2003 - Coolant Leakage After Lower Intake Gasket Replacement


Aug 16, 2014

Well, I decided to take on the dreaded task of replacing the lower manifold intake gaskets and put in new isolator bolts. It was a major undertaking, and when I finally finished the oil change and fired up the car, it sounded fine. Then I checked under the hood.

I saw coolant spurting out the side of one of the hose connections that I had to take off and put back on. I thought the gasket on it looked pretty worn, but wasn't expecting this!

Unfortunately I don't know the name of the hose connection to pick up a gasket at the store ... it's the larger lower hose that is bolted on to the lower intake, not the hose slightly above it that has the plastic clips.

What is the name of this hose connection so I can try and find one at the store? It's a 2003 Windstar model.

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Putting in the Dorman replacement and noticed that the front cylinder drivers side (#5) had a decent amount of coolant in it.. None of the others did. I've drained the coolant already and was wondering should I just put this back together and see?

The water outlet crossing has a hole right next to this cylinder and I can't see any cracks and not sure if the gaskets were leaking under it.

Seems like if the head gasket was blown I would see it in more cylinders? It never smoked or run bad before I got this leak... Drove it maybe 10 miles with it leaking out onto Cyl#1. Ran fine, never missed.

I just don't want to put this back together if the head gasket is blown but I don't know what to do.

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1) I know I didn't post much info, but does this seem like an intake manifold leak?

2) Are there any special tools needed to change out the gasket myself?

3) Can you all recommend any replacement gaskets? I found a few different manufacturers of gaskets, but I'm sure some are better than others.

4) Can this issue cause the computer to throw the loose gas cap code (P0455 if I recall correctly).

5) Would it be worth it to just get a new truck? I really wanted a diesel in the first place, but I also hate to give up on a nice truck with only 115,000 miles.

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