Pin hole leak in temperature sensor housing pipe

[mikkelstuff]

I discovered a pin hole leak spraying coolant from just above the heater hose that attaches to the pipe out of the temperature sensor housing. I thought it was the heater hose but have since learned that that thin wall pipe can develop pin holes over time.

Of course that housing is in a terrible place immediately behind a rigid A/C line to the compressor. The radiator and fan shroud must come out. It would nice to remove the fan, one big nut, but mine did not want to come free.

Also
the danged heater hose did not want to come loose at the temperature sensor housing even with the hose clamp removed. So regrettably I went after it with a long screw driver and hammer. The hose finally came off BUT I smashed and holed that thin pipe out of the housing for the heater hose. Well it was bad anyway.

I went to the Ford dealership today to order the part - at least 3 days to get one. The part number is F772-18599-AA. NAPA it turns out also carries the housing but again a 3 day wait.

 

[mikkelstuff]

When desperate:

As removed from the intake manifold:

So I cut off the thin wall pipe and pressed in as best I could a scrap piece of 1/2" heavy wall copper tubing.

Not shown above but I tinned the copper tubing and the steel temperature sensor housing as best I could before pressing in the copper tubing.

Then I soldered the copper tubing to the housing. Not the best with only a MAP gas torch but all I had.

My Dad, a WW-II radiator repairman, would have done a much neater job but I did the best I could.

So I reinstalled all, refilled the water and antifreeze, warmed the engine to normal operating temperature, and made a run around the block with no leak.

I have a new replacement housing coming from NAPA which I will store away just in case.

Neverless I am declaring victory!

 

[pentode]

Nicely done.

 

[SenorNoob]

Good repair. Looks like the bottom thread is pretty corroded too. Someone didn't change coolant often enough or ran creek water the way that looks. Keep an eye out for the hose to pop off with the lip. It's easier than you'd think...