"DougC" wrote in message
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On 1/17/2012 6:06 AM, Rick wrote:

"DougC" wrote in message
...
On 1/16/2012 8:06 PM, Rick wrote:


There was a technical service bulletin released (96-12-17) for radiator
tank leaks at cold temperature, The replacement radiator (F67Z-8005-BA)
had a revised seal.




There is also a TSB for a revised water pump on the 4.0L, 97-18-9, for
thumping and/or erratic temp gauge. The part number for that pump is
F7PZ-8501-AA. I believe that also had an impeller change but I can't
remember the difference offhand.

There is also TSB 99-7-2 , referring to the coolant bypass kit for the 4.0
engine in Explorers. It makes no mention of any previous upgrades to the
radiator or water pump.

------

There was also a special water pump and a bypass kit, for the 4.0 liter
engine in the Explorers. At different times Ford said each would fix the
same problem, and now neither is available. I have the Ford page printouts
around somewhere, and there's lots of references to them online.

The bypass kit for the 96 Explorer is # F8PE-8522-BA

here is one of many forum postings referring it-
http://www.ford-trucks.com/forums/17...-and-down.html

People online all say how to fix the problem of the radiator leaking/temp
gauge going up and down/heater thumping, and they all say something
different...

It is 'definitely' either the water pump, the radiator, the radiator cap,
the temperature sensor, not using the dealer-source parts for any of
these,,, or not having the bypass kit installed--but what I noticed is
that nobody who got the bypass kit seems to keep posting that the problem
wasn't fixed. Everybody asks where to get the bypass kit, and Ford hasn't
made any new ones since 1998.

First I want a bombproof radiator, and next I'm making a bypass kit myself
(since I have tried most of the other stuff already, with no success more
than two years). If the gasket of the clamped-together radiator still
leaks, then I can just have the radiator shop TIG it together instead.


Good thing you have a copy...99-7-2 was superseded by 99-23-8, which "is
outdated and no longer available"

I don't recall seeing a bypass kit for the 4.0L. The 3.0L Ranger had a tee
in the lower radiator hose.

Usually the header is welded directly to the tank, no crimp ring or gasket.