What's the deal with ford replacement parts?

[TomT]

Have to rant about my wife's 97 Expedition here since there's no decent expedition forum out there. It's now in the shop getting the 4th heater core installed within the last year. The shop is buying them direct from a Ford dealer. The last 3 have only lasted 6-8 weeks.

I haven't been out any money since the first installation but the shop is wishing they never saw me. It's a MAJOR undertaking to pull a heater core. It's costing the shop a lot of lost time and salaries. They are telling me now that they will not get another heater core from Ford, instead find an aftermarket one. Can't blame them. After the 2nd replacement, the shop did find a TSB that said to ground the core (helps prevent electrolysis), which they did. Didn't help. Has had full flush (several) so it's not something in the coolant. The only explanation is crappy Ford replacement cores.

Anyone want to buy an Expedition? I'm selling it and buying her something reliable. Like a Toyota.

 

[Todd Z]

It could always be the people installing it, IF it is that much a PITA, it may not be the parts, but the installer Maybe they are missing something like a hoses be bad, brass get crushed and leak causing it to seem the heater core was bad again, leaking clamp, bad clamp etc.

And Ford does not manufacturer its own parts, they probably buy the core from modine...

Todd Z

 

[TomT]

This is not a fly-by-night company. I have been using them for years. They have excellent mechanics. (Better then the local Ford dealer, that's for sure). I had them replace all the heater hoses the first time, so it's not a connection. It's definitely something within the core itself. I have never seen anything like this and neither have they. If I was them I would refund my original money and tell me to take it to Ford and get it fixed. Then it would become their problem.

 

[Robert Poole]

Ford don't make the parts anymore. they used to at one time. now all of it is made by vendors, that tend to make them as cheap as possible. With a 97 expy, chances the part is an aftermarket part. As far as trading the Expy, if the truck has been reliable except for the heater core, I would give the vehicle the benefit of the doubt if the heater core is the only major problem.



have a good one



Bob

 

[TomT]

Having to replace a heater core ebvery 6 weeks is a major inconvenience. The vehicle was great for the first 100,000 miles but since then it's had a lot of problems. It seems to be in the shop more than in my garage these days. And I don't want my wife driving around in an unreliable vehicle.

 

[Todd Z]

Take the old one and look at it, see where it is failing... Then re solder that joint on the new one before you install.....

just an idea...

Todd Z

 

[Richard L]

TomT,

A good radiator shop can pressure test the heater core and make any repairs. I doubt that a new core that leaks would be so bad to be beyond repair. Perhaps it was dropped in shipment or they handled it rough when installing it and cracked a solder joint?



I would be curious as to what you are seeing as symptoms of a leaking heater core. It's possible the problem was misdiagnosed and you are replacing good heater cores because the problem is elsewhere.



...Rich

 

[TomT]

Whether they replace it or repair it, the core still has to be removed and that invloves about 8 hours of work. They are getting the replacement cores from Ford for free because they are in warranty, so I'm sure that's why they are just replacing them. But you have a good idea Todd. I will ask them if the cores are failing in the same spot. They did say they found electrolysis again in the coolant despite flushing it and grounding both the core and the engine. Where does electrolysis come from and why was it not a problem the first 100,000 miles? I'm stumped and so is the shop.

 

[Mark Grumpy]

Electrolysis is chemical decomposition or change. It occurs in electrolyte, which is basically an electrical conductor.

Somehow, somewhere current is entering the coolant as it flows through the core. Grounding the core would give the current an easier path in and out. Seems to me that instead of grounding the core it should be isolated or insulated from ground.



grump

 

[Todd Z]

I agree with grump.. BY grounding the core ( giving the electricity the path of least resistance), it will be forced to flow through the heater core...



It may be getting voltage from touching the fire wall, or a screw in the heating box or even through the coolant or hoses....



Can try grounding the clamps and not the core..

Todd Z

 

[Mark Grumpy]

Another thought - the current may not be entering at the core itself. It could already be in the coolant. The core, by being grounded, possibly just on a screw head like Todd said or directly by the mechanic, gives it the easiest path to ground. And I'd be willing to bet the heater core is the flimsiest, most vulnerable metal of all the components the coolant flows through.



grump

 

[TomT]

I agree with what your saying. But the first 2 cores were not grounded and still failed. And even Ford's TSB says to ground the core. Is Ford wrong? Myself, I am clueless. I just want it to last more then 6 weeks.

 

[Richard L]

TomT,

The electrolysis in the cooling system is caused by the PH of the coolant. Electrolysis occurs then two different metals are exposed to the same acidic solution. Metal molecules are eaten off of one piece of metal and deposited on the other metal. This is exactly how chrome plating is done.



Heater cores are made mostly of copper and aluminum and may also have tin, lead, and silver as a solder. If the coolant has not been changed, or the wrong coolant was used, it may be promoting the electrolysis.



You still have not answered what symptoms you are having that indicates that you have a leaking heater core?



...Rich

 

[TomT]

The core is leaking and blowing a fog of antifreeze inot the inside of the car. No doubt the core is bad. The engine has been completely flushed each time to no avail. To bad they don't make a plastic core.

Does anyone know of an additive that can be put in to help control the electrolysis?

 

[EddieS'04]

What if Ford is getting a bad batch of cores from China...anything is posible...manufacturing defects, such wrong alloy composition...

 

[Gypsy me]

Expediton forum on this site

 

[TomT]

I know about the Expedition forum GM but lets face it, not to many people read it. (I think it has 5 whole posts ). This problem I'm having could carry over to Tracs as well. If and when you need a new core. This is a problem that needs to be addressed by Ford. In the meantime I will take any help I can get.

 

[Michael Cacioppo]

If this was a generic problem I'm sure the shop would have seen it before. It seems to be realtively unique to your truck. A couple of thinks to question:



Have you used the same antifreeze type before having any problems?



Have different types been tried during the miriad of repairs, i.e. phospahte free, etc.



Has the pressure cap been checked/ changed? It might not be working and over pressuring the core.



Are the failures in the same spot?



I'd changeout the cap, especially if its the original.



Just some thoughts.

 

[Todd Z]

Make sure they are not using recycled antifreeze also..

Todd Z