Infamous 'defrost only' failure mode strikes again.

[Jeff_Birt]

Diagnosed 'defrost only' on my 2011 w/4.0 to the infamous cracked vacuum line to the reservoir. The more I tried peeling back split loom surrounding the weeny plastic line the more little pieces it shattered into. Looks like whole tree of vacuum lines is available from Ford for about $65. Some places discount it $20 but charge $20 shipping so it is a wash. Getting to where it connects to intake looks like a load of fun. Have not found a 'how to' yet but line to reservoir runs back behind engine. Can't tell where it connects. I have factory service manuals but of course they show nothing.

Will swing by Ford dealer tomorrow to see how fast them can get one and how $$ they want.

https://www.fordpartsgiant.com/parts/ford-connector_5l5z-9e498-ca.html

 

[bobbywalter]

well....


its vacuum line. not willing to spend alot on shit that dont matter.....obsolete parts... seems to be the second it rolls out of the dealership now...

 

[Jeff_Birt]

Found Dorman sells the correct size plastic (PVC) tubing, 2.5mm ID x 4mmOD (Dorman 47418). Local car parts place wants $12 for 3'. Ouch! Found 16' of same size tubing in silicone on Amazon for $8. Bought the silicone tubing to see if it will work.

 

[Vinny68]

I have this same issue where air only comes out of the defrost vent no matter the setting. Didn't realize this was a common problem. Does anyone have instructions for how to replace this vacuum line? Mine is a 1997 with the 4.0L.

 

[Jeff_Birt]

I have this same issue where air only comes out of the defrost vent no matter the setting. Didn't realize this was a common problem. Does anyone have instructions for how to replace this vacuum line? Mine is a 1997 with the 4.0L.

Tons of videos on YouTube though I have not found one that covers my 2011 precisely. The trick it to track down where vacuum line broke, most seem to be on passenger side of engine where it travels over exhaust manifold or right at the vacuum reservoir.

 

[Jeff_Birt]

Saw a video where guy described the same issue I had with broken vacuum line crumbling. He had tracked down where it plugged into intake manifold near coil pack. Confirmed same on my truck.

Pics "Source_at_Manifold.jpg" shows line where it attaches to manifold. "Break_at_1way.jpg" shows where it broke at a 1-way valve on its way down to vac reservoir. Looks like it will be easy enough to replace just the broken line. Evidently another common location for breaks in the line running from vac reservoir into cab.

 

[Jeff_Birt]

Got the silicone hose in from Amazon. It is not ideal but works. It is rather 'squishy' and had to force into the original rubber boots. The HVAC does work properly now though.

In the 'Source_at_Manifold' image above the vacuum fitting you see in center has two of the original PVC tubes, the right one goes over to the HVAC vac reservoir. The left one goes down to and EGR solenoid. It was shattered into pieces as well and was replaced. Interestingly the line from EGR solenoid to EGR valve is a different type of plastic and is still in good shape.

Not quite satisfied with the silicone tubing though. Found some 4xxOD x 2.5mmID black nylon tubing on Amazon this evening. Will try this next. Why? Because same stuff still work on my 1990 BII so may as well find the stuff that is easy to install and that works well.