Coolant leak from crossover plug - 2003-04 Mach 1 Registry Owners Club

brtnstrns · 03-25-2015, 07:59 PM

Has anyone ever dealt with this before? The coolant leaked from the crossover plug when I first put the engine back in the car so I replaced the o-ring with a new one. Now it seems it's leaking as well after a couple weeks. The only problem is that I don't know if it's leaking due to the bore of the crossover plug boss being too large for some unknown reason or the aftermarket plug, which have a very good reputation but perhaps mine isn't up to par.

Any ideas?

canadianmach1 · 03-25-2015, 08:43 PM

Unless you used the wrong size oring I would say it is the plug that is leaking

DSG2003Mach1 · 03-25-2015, 09:58 PM

if you havent had a problem before I would guess that the aftermarket plug is slightly out of tolerance

brtnstrns · 03-25-2015, 11:16 PM

Quote:

Originally Posted by DSG2003Mach1

if you havent had a problem before I would guess that the aftermarket plug is slightly out of tolerance

May have to try to billetproshop one that has two o-rings. Another $50 for one though.

I really need to get out of the car game - this nickel and dime **** is going to make me go broke

NastyNate · 03-26-2015, 12:15 AM

My plug stripped out the threads in the coolant crossover. i used a marine epoxy last time to seal it up. Im about to flush my coolant weekend. Gonna try to tap once size larger and get a new plug.

Teufel-Mach1 · 03-26-2015, 07:11 AM

If the ring is the issue, I used an O ring from home Depot. Can't remember the size off the top of my head but I took the plug in and replaced the flat ring with trial and error. The rings cost me like 2 bucks for a few. Plumbing had them if I remember correctly, it's been 2 years and not a drop since I replaced the flat worn ring.

canadianmach1 · 03-26-2015, 07:48 AM

MMR sells plugs here is the link
http://www.yellowbullet.com/forum/sh...php?p=29280410

not a gt · 03-26-2015, 10:41 AM

I would hit a junk yard and find a stock plug,(the one in pic looks like an oil pan drain bolt to me), and make sure female threads are decent. As big as lip looks on the bolt, maybe a thin plastic washer what is on a oil pan drain bolt sometimes

311-420 · 03-26-2015, 10:49 AM

Quote:

Originally Posted by brtnstrns

May have to try to billetproshop one that has two o-rings. Another $50 for one though.

I really need to get out of the car game - this nickel and dime **** is going to make me go broke

Easy there ghost rider. Let's not make any rash decisions.

01yellerCobra · 03-26-2015, 10:56 AM

I'd try another o-ring before buying a new plug. It might be the wrong size.

not a gt · 03-26-2015, 11:00 AM

Quote:

Originally Posted by 01yellerCobra

I'd try another o-ring before buying a new plug. It might be the wrong size.

True, Ford made sure there specific o rings are off enough you HAVE to get it from them..does it have a torque value as well??

canadianmach1 · 03-26-2015, 11:13 AM

Quote:

Originally Posted by not a gt

True, Ford made sure there specific o rings are off enough you HAVE to get it from them..does it have a torque value as well??

These O-rings seal from the side , so it doesn't really matter how tight you get the plug

brtnstrns · 03-26-2015, 11:54 AM

Quote:

Originally Posted by not a gt

I would hit a junk yard and find a stock plug,(the one in pic looks like an oil pan drain bolt to me), and make sure female threads are decent. As big as lip looks on the bolt, maybe a thin plastic washer what is on a oil pan drain bolt sometimes

No oil drain plug, it's this exact one:
http://www.mach1registry.org/forums/...d.php?t=127025

Quote:

Originally Posted by 311-420

Easy there ghost rider. Let's not make any rash decisions.

You know emotional decisions are the most logical decisions...

Quote:

Originally Posted by 01yellerCobra

I'd try another o-ring before buying a new plug. It might be the wrong size.

Yeah I'm going to go by the Sears down the street from me and see if I can try another one - it's a "appliance and hardware" store and they've got a crazy amount of stuff you can't find at a normal autozone/home depot/lowes.

Quote:

Originally Posted by not a gt

True, Ford made sure there specific o rings are off enough you HAVE to get it from them..does it have a torque value as well??

No torque value - most people over-torque them and damage them, but mine is just snug due to the assumption that the o-ring is doing its job.

311-420 · 03-26-2015, 12:01 PM

Quote:

Originally Posted by brtnstrns

You know emotional decisions are the most logical decisions...

Hasty and logical are not synonyms sir!

Trust me I know how you feel though.

brtnstrns · 03-26-2015, 06:36 PM

May have found the problem *facepalm*

I didn't have time to check it yesterday, just saw the coolant when I went outside to grab a picture of my engine bay. I guess although the thickness of the o-ring was likely correct, the diameter was a bit too small and over-stretched it's welcome...

not a gt · 03-26-2015, 06:46 PM

Glad you found it, I had the same thing happen on one of the tube o rings, doesn't take much, put a little vaseline on that bad boy and screw back in lol

kens99 · 03-29-2015, 08:28 AM

Did you get the correct new O ring from Ford?

brtnstrns · 03-29-2015, 11:06 AM

Quote:

Originally Posted by kens99

Did you get the correct new O ring from Ford?

No, using a 3/32" thick 1/2" inner-diameter o-ring I got from Sears. We'll see how long it lasts.

03-25-2015, 07:59 PM	#1
brtnstrns Registered User Join Date: Jul 2012 Location: Houston, TX Posts: 597	Coolant leak from crossover plug Has anyone ever dealt with this before? The coolant leaked from the crossover plug when I first put the engine back in the car so I replaced the o-ring with a new one. Now it seems it's leaking as well after a couple weeks. The only problem is that I don't know if it's leaking due to the bore of the crossover plug boss being too large for some unknown reason or the aftermarket plug, which have a very good reputation but perhaps mine isn't up to par. Any ideas?

03-25-2015, 08:43 PM	#2
canadianmach1 Registered User Join Date: Mar 2005 Location: edmonton canada Posts: 765	Re: Coolant leak from crossover plug Unless you used the wrong size oring I would say it is the plug that is leaking __________________ mods, bbk longtubes, bbk xpipe , slp powerflo catback, EMP Stewart water pump, h&r springs , tokico adjustable shocks, php spacer, 4drilled/slotted rotors, , vortech with air/air, Anderson powerpipe, cobra tank/pumps, ford racing t56 6spd, mgw shifter,center force clutch, 410 gears , moser axles, ford racing carrier ,steeda alum lower control arms ,cobra bumper , and mirrors

03-25-2015, 09:58 PM	#3
DSG2003Mach1 700 HP Mach Join Date: Nov 2003 Location: Orlando, FL Posts: 8,384	Re: Coolant leak from crossover plug if you havent had a problem before I would guess that the aftermarket plug is slightly out of tolerance __________________ 03 dsg mach1 - MPR built 9.5:1 motor, D1, cams, ported intake, full exhaust, magnum t56, built rear, E85 etc... '12 F150 FX2 Supercrew with Ecoboost daily beater

03-26-2015, 12:15 AM	#5
NastyNate Registered User Join Date: Mar 2008 Location: Jersey Shore Posts: 1,349	Re: Coolant leak from crossover plug My plug stripped out the threads in the coolant crossover. i used a marine epoxy last time to seal it up. Im about to flush my coolant weekend. Gonna try to tap once size larger and get a new plug.

03-26-2015, 07:48 AM	#7
canadianmach1 Registered User Join Date: Mar 2005 Location: edmonton canada Posts: 765	Re: Coolant leak from crossover plug MMR sells plugs here is the link http://www.yellowbullet.com/forum/sh...php?p=29280410 __________________ mods, bbk longtubes, bbk xpipe , slp powerflo catback, EMP Stewart water pump, h&r springs , tokico adjustable shocks, php spacer, 4drilled/slotted rotors, , vortech with air/air, Anderson powerpipe, cobra tank/pumps, ford racing t56 6spd, mgw shifter,center force clutch, 410 gears , moser axles, ford racing carrier ,steeda alum lower control arms ,cobra bumper , and mirrors

03-26-2015, 07:11 AM	#6
Teufel-Mach1 Registered User Join Date: Aug 2013 Location: San Antonio Posts: 9	If the ring is the issue, I used an O ring from home Depot. Can't remember the size off the top of my head but I took the plug in and replaced the flat ring with trial and error. The rings cost me like 2 bucks for a few. Plumbing had them if I remember correctly, it's been 2 years and not a drop since I replaced the flat worn ring.

03-26-2015, 10:41 AM	#8
not a gt Registered User Join Date: Mar 2007 Location: Waaayy out in the country,leave your GPS at home! Posts: 4,825	Re: Coolant leak from crossover plug I would hit a junk yard and find a stock plug,(the one in pic looks like an oil pan drain bolt to me), and make sure female threads are decent. As big as lip looks on the bolt, maybe a thin plastic washer what is on a oil pan drain bolt sometimes __________________ 2003 DSG Mach 1-03 Cobra Term/T56 swap: 2.3L Whipple,3.37 Upper,4 lb.lower, ID 1000 injectors,LCD cooling mod,Billetflow idlers,200A Alt,oil cooler delete with MMR adapter plate,MM oil filter kit,FrozenBoost Heat Exchanger Flowtech L.T., Maganaflow O/R X with Magnapacks, FRRP D.S.,T-56 with 26 spline input shaft and anti venom mod with reverse lockout box, FR steel flywheel,Spec Stage 3+,Moser 31 spline axles,FR 3.73 gear Tuned by B.Kurgan 601Hp/558/Tq

03-26-2015, 10:56 AM	#10
01yellerCobra Registered User Join Date: Jan 2013 Location: San Diego, CA Posts: 1,104	I'd try another o-ring before buying a new plug. It might be the wrong size. __________________ New Ride: 2004 Mystichrome Cobra-Accufab SBTB and plenum, Steeda 2.8" upper, Bassani X, Borla Stingers, Mcleod RXT, MGW shifter, Level 5 halfshafts, chrome FR500's, Stiffler's FIT system and DS safety loop, GT pumps, BA3000, tuned by owner

03-26-2015, 06:36 PM	#15
brtnstrns Registered User Join Date: Jul 2012 Location: Houston, TX Posts: 597	Re: Coolant leak from crossover plug May have found the problem facepalm I didn't have time to check it yesterday, just saw the coolant when I went outside to grab a picture of my engine bay. I guess although the thickness of the o-ring was likely correct, the diameter was a bit too small and over-stretched it's welcome...

03-26-2015, 06:46 PM	#16
not a gt Registered User Join Date: Mar 2007 Location: Waaayy out in the country,leave your GPS at home! Posts: 4,825	Re: Coolant leak from crossover plug Glad you found it, I had the same thing happen on one of the tube o rings, doesn't take much, put a little vaseline on that bad boy and screw back in lol __________________ 2003 DSG Mach 1-03 Cobra Term/T56 swap: 2.3L Whipple,3.37 Upper,4 lb.lower, ID 1000 injectors,LCD cooling mod,Billetflow idlers,200A Alt,oil cooler delete with MMR adapter plate,MM oil filter kit,FrozenBoost Heat Exchanger Flowtech L.T., Maganaflow O/R X with Magnapacks, FRRP D.S.,T-56 with 26 spline input shaft and anti venom mod with reverse lockout box, FR steel flywheel,Spec Stage 3+,Moser 31 spline axles,FR 3.73 gear Tuned by B.Kurgan 601Hp/558/Tq

03-29-2015, 08:28 AM	#17
kens99 Registered User Join Date: Oct 2005 Location: Burlington, NJ Posts: 46	Re: Coolant leak from crossover plug Did you get the correct new O ring from Ford?

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