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Discussion Starter #1
I have a couple of questions to ask everyone here, that owns a Gen III vulcan.

1st off, who here has had the rusted out freeze plug nonsense happen to their car, and how many that did, have had them all replaced under the recall (you know, the one that they forgot to tell everyone about? the one that expired in 2000)

I know it's too late, and my car never had this done, oddly. The car SHOULD have had it done, it was in for repairs to the dealership on a few occasions, one time that is documented, is 1999 for a new PCM.

I just bought this car a week or 2 ago, and freeze plugs started poppin' I replaced one on the head, and now I have to do one on the front of the block... QUESTION... HOW MANY IS THERE, AND WHERE ARE THEY LOCATED???????? I cannot seem to get the answers on this anywhere on the net.

And for those of you, that have faced this dilemma after the recall expired, how did you deal with this? Any help from the dealership?

ANY HELP I CAN GET IS GREATLY APPRECIATED!
 

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Discussion Starter #2
You can't tell me, with all the TSB's I've seen, and all the complaints acrossed the net, that none of you have ever been down this road!!!

Please? I'm stuck. I need help with this!!!
 
J

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I never had any type of problem with what you're describing on the Gen 3 vulcan I had.
 
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I can access alldata online and view all recalls and tsb's...There are no recalls dealing with the freeze plug. And the only TSB is this:

QUOTE
Article No.
96-7-8

03/25/96

^ COOLING SYSTEM - DRAIN PLUG ON BLOCK IS OVERSIZED - 3.0L ENGINE - VEHICLES BUILT FROM 8/1/95 THROUGH 8/5/95 - SERVICE TIP

^ ENGINE - 3.0L - DRAIN PLUG ON BLOCK IS OVERSIZED - VEHICLES BUILT FROM 8/1/95 THROUGH 8/5/95 - SERVICE TIP

FORD:
1996 TAURUS

LINCOLN-MERCURY:
1996 SABLE

LIGHT TRUCK:
1996 WINDSTAR

ISSUE:
The right side engine block drain plug hole and plug is oversized. This was done on a limited number of engines and will have no effect on engine coolant contents.

ACTION:
Removal of plug is not advised, but if need to replace plug arises, install a standard 1/4"-18 PFT pipe plug (F1ZZ-6026-
. Refer to the following Service Procedure for details.

NOTE : DO NOT REMOVE THE RIGHT SIDE SQUARE HEADLESS SOCKET PIPE PLUG IF AT ALL POSSIBLE. IF IT IS NECESSARY TO REMOVE THE RIGHT SIDE PLUG TO DRAIN FLUID FROM THE RIGHT WATER JACKET AREA, REPLACE THIS PIPE PLUG BACK INTO ONLY THE RIGHT SIDE DRAIN HOLE.

SERVICE PROCEDURE

1. Obtain a standard 1/4-18 PFT pipe plug (F1ZZ-6026-
.

2. Install the plug using Pipe Sealant with Teflon (D8AZ-19554-A).

3. Install plug into block to the standard torque of 20-28 N.m (14.8-20.7 lb-ft).

4. For proper thread engagement, the face of the plug should be flush or outward of the block's machined boss surface.


PART NUMBER        PART NAME

F1ZZ-6O26-B        1/4"-18 PFT Pipe Plug

D8AZ-19554-A        Pipe Sealant with Teflon

OTHER APPLICABLE ARTICLES: NONE

WARRANTY STATUS: INFORMATION ONLY

OASIS CODES: 402000, 499000[/b]
And this is still not what you are describing...
 

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I havent ever heard of anyone having a problem with their freeze plugs on the vulcan....this is the first.

My gen3 vulcan hasnt had any problem with then either. I stand at 124,000 miles.
 

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Discussion Starter #7
Are you kidding me? Go check a little more, find out that there was a rusty coolant recall campaign that lasted from 1998-2000 that involved rotting freeze plugs, the recall included replacing the expansion tank, all freeze plugs, a chemical flush, and a coolant by-pass kit being installed and most of the time, a water pump. I cannot believe none of you have heard of this. Mine has all rotted freeze plugs @ 106k, and the car is near mint.

It's out of control, and it makes me upset. Especially because the car was back to the dealer in 99 for a PCM replacement, and they never installed the by-pass kit as they were supposed to.

There was a recall sent out to all 96 - 97 owners, from what I have read. I found several threads about it online, talking about it as well as the TSB showing this recall.

Actually, I even got a PDF from a member of the forum last night of the TSB.

Anyone ever noticed how rusty the coolant gets on these cars? Well, look into it.
 

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Discussion Starter #8
General Recalls
TSB Number Issue Date TSB Title 98B27 AUG 98 Campaign - Coolant By-Pass Kit Incorrect
98B23 JUL 98 Campaign - Cooling System By-Pass Installation
98B18 APR 98 Campaign - Cooling System By-Pass Kit Installation
 

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Originally posted by jdaniels@Dec 30 2003, 04:52 PM
Are you kidding me? Go check a little more, find out that there was a rusty coolant recall campaign that lasted from 1998-2000 that involved rotting freeze plugs, the recall included replacing the expansion tank, all freeze plugs, a chemical flush, and a coolant by-pass kit being installed and most of the time, a water pump. I cannot believe none of you have heard of this. Mine has all rotted freeze plugs @ 106k, and the car is near mint.
Man,
short of digging up Henry Ford what would you like us to do.
You bought a seven year old car without doing your homework.

At this point I would get it fixed and get over it
 

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I know most of us vulcan guys can tell you about rusty coolant and heater core issues but I have never heard of any problems or recalls on frost plugs. Seems like it may be a specific problem to a build date not a general recall. Also if you look it is called a Technical Service Bulletin not a recall. A TSB is a issue discovered by Ford or someone else and includes steps to do the repair properly not necessarily a defect.
 

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Originally posted by jdaniels@Dec 30 2003, 04:52 PM
Are you kidding me? Go check a little more, find out that there was a rusty coolant recall campaign that lasted from 1998-2000 that involved rotting freeze plugs, the recall included replacing the expansion tank, all freeze plugs, a chemical flush, and a coolant by-pass kit being installed and most of the time, a water pump. I cannot believe none of you have heard of this. Mine has all rotted freeze plugs @ 106k, and the car is near mint.

It's out of control, and it makes me upset. Especially because the car was back to the dealer in 99 for a PCM replacement, and they never installed the by-pass kit as they were supposed to.

There was a recall sent out to all 96 - 97 owners, from what I have read. I found several threads about it online, talking about it as well as the TSB showing this recall.

Actually, I even got a PDF from a member of the forum last night of the TSB.

Anyone ever noticed how rusty the coolant gets on these cars? Well, look into it.
Ive heard about the brown coolant deal and a coolant bypass kit, but ive never heard anything about the freeze plugs. My car has the brown coolant "problem", which isnt really a problem at all.
 

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Discussion Starter #12
Yea, it was a campaign recall. It was a defect. Thats why there was a by-pass kit. The freeze plugs are what was affected the most from what I've read. Hope you guys don't have the same troubles!!!

Question, does anyone know where all the freeze plugs are? I had one on the head go, and one on the block go. It sucks!
 
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We have a 97, and apparently it had the bypass done before we bought it in 99. Still has brown coolant though...
 

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I think all you guys are right, actually. The TSB jdaniels is referring to is Article No. 01-11-6 which covers the now infamous "brown coolant" issue on '96-'98 models.

Although not specifically mentioned in the TSB, freeze plugs rusting and/or blowing out is just one of the many ways in which the brown coolant problem manifested itself in the 3.0L Vulcan. The list also includes (as set forth in the TSB):

- Contaminated/corroded coolant
- Leaking/Cracked/Discolored Coolant Overflow bottles
- Vibration or thumping from engine
- Leaking heater core
- Coolant overflow
- High temperature gauge readings
- Fluctuating temperature gauge
- Stuck Thermostat
- Heater hose leaks
- Leaking head gasket
- Lack of heat

And it was more than just a few cars that had the plug problems, too. Take a look:

http://www.cartrackers.com/Forums/live/Ford/132.html

On Edit: I don't know for sure, but it may have been one of those limited "secret recalls" where unless a customer actually has a problem and goes to the dealer within a certain time period to get it fixed, it will not get done. No formal notification program, no publication, nothing. Almost like "don't ask, don't tell".
 

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Discussion Starter #15
Ford claims they contacted owners. Still a possibility the kit may be in my car, but I'm not sure what to look for. Bob, any idea?

I know guys, it's weird, i just wanted to know if anyone else faced the problem here and how they went about getting it fixed, It's a royal pain to replace all those little dinglehoppers. lol.
 

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Do I need to worry about Freeze plugs here in CA. Never does get below 40.....ever. :cool:

-mobiuslogic
 

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Originally posted by mobiuslogic@Dec 31 2003, 02:39 AM
Do I need to worry about Freeze plugs here in CA. Never does get below 40.....ever.

-mobiuslogic
The freeze plug problem is not dependant upon ambient temperature...
 

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Wasn't there a discussion about the brown coolant thing back in the day? I think one of the theories floating around was that the coolant was "corroding" from electrolysis. If the engine and/or radiator isn't grounded properly, this is certainly a viable theory.

I only found this article in the archives.
 
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Interesting information Dan. I need to check mine, since I keep blowing head gaskets. That may be the problem.

As far as the bypass, I have no idea what it looks like. I do know that they did not do the whole job though, as my coolant tank leaked and was stained brown about one year after we bought the car. I replaced it myself.

From what I was told by a former Ford tech was that it's an inherent design problem with the Vulcan in the Gen 3, something about the casting material. He said a chemical flush, and then an additive to "seal" the block's water jakcets would work, but it didn't.
 

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Electrolysis is definetely relevant to the the Brown Coolant equation. But it probably should be considered as much a contributing factor as a root cause because I'm pretty sure the Vulcan can still develop brown coolant problems without having electrolysis problems. Anyway, more on electrolysis here:

Electrolysis Problems Continue to Mount

This is why I am always preaching how important it is to flush your cooling system regularly and to use distilled water!
 
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