Intercooler pump install... anything to look out for?

[WA 2 FST]

The pump on my son's '04 is dying. Terry installed a manual override switch, and we were under the hood adding a few things and it wouldn't kick on. A little "love tap" with a butt end of a screwdriver and it whined for a bit. Very sluggish when it kicks on, and a couple more taps and it starts running good. So... he's under instructions not to drive the truck hard, which he only does a few spirited romps and that's really about it anyway. Probably the only reason we haven't had any issues til now... who knows how long it hasn't been working... probably a couple of months at the most, since I check it when we do oil changes. I ordered a new pump and should have it by middle of next week. Any "gotchas" with this install? From the looks of it, it appears pretty straight forward. How much coolant will I need once I drain everything out? TIA.

[WA 2 FST]

NVM on the amount of coolant. Manual says 4.2 qts, so I'll do half-and-half with distilled water. Again, it looks pretty easy... two screws/bolts hold it in the bracket and then it just pops out, right?

[L8 APEX]

Ah huh.... The petcock to drain the stock IC is on the passenger side I believe. The main issue is getting the air out of the new pump. Sometimes blowing in the tank works sometimes. Two 8mm head bolts on top pinch the bracket. Electric is an easy squeeze connector. It is about a one gallon system and Ford used almost straight antifreeze. You can dilute and add something to lower the water surface tension like RP Purple Ice or red Line water wetter.

[WA 2 FST]

Thanks Terry. I have the aftermarket H/X you installed, so I now realize it is more than 4.2 qts capacity. Will look for a drain cock... was originally just figuring I'd disconnect a hose to the pump and let it drain. My plan was to run the pump with the auxiliary switch you installed as I am filling the tank and "burp" the system that way... but I may be thinking it is simpler than it really is. I definitely was not going to use straight antifreeze... was planning something like a 50/50 mix of AF and distilled water.

[L8 APEX]

The aftermarket units ar usually closer to two gallons. About a third of that will stay in the engine side of the system. Pouring in pre mixed is the easiest way to be correct. You may have to drop the rubber flap to get to the drain cock. Pulling the hose works as well. Some crafty people pinch the hoses with long billed vise grips and they don't lose much at all...

[WA 2 FST]

The aftermarket units ar usually closer to two gallons. About a third of that will stay in the engine side of the system. Pouring in pre mixed is the easiest way to be correct. You may have to drop the rubber flap to get to the drain cock. Pulling the hose works as well. Some crafty people pinch the hoses with long billed vise grips and they don't lose much at all... I'm glad to know my mechanical instincts (which are not much to begin with) haven't completely dissolved over the past few years. I considered pinching the hoses with vice grips. Then again, flushing the system can't hurt, either. Appreciate all the help, Terry. Shouldn't be a tough project to tackle and complete. For now, he is popping the hood, flipping the override switch and driving it with it always on... then if he is parked for any amount of time, he shuts it off. Once it is running, it is fine... it just doesn't always kick on by itself. Should have the part soon anyway.

[WA 2 FST]

Terry... thanks again for the help. Definitely an easy install. Having the aftermarket H/X may have made it easier, I don't know, but the drain cock was easily accessible. Took about 35 mins including jacking up the truck in our garage. I probably should go ahead and do this on my daughter's 2000 truck. It has only 33k miles on it, but who knows... my son's '04 has 47k on it. We installed a C&L plenum, Accufab TB, and a 6lb ring on the Metco lower hub. JDM sent me a new tune for it. Truck runs really strong. He said it is significantly faster from 45+ in 2nd gear (when you're going too fast to have it downshift back into 1st). My son knows to be careful on high-end runs (which he doesn't do, but I told him exactly what you told me after installing the Kenne Bell... high-speed pulls puts a ton of load on the motor... could lead to BOOM, so _don't_ do it). I rode along with him and it does pulle really well. I doubt it is at 450rwhp where it was when I had the KB on it, but I'm guessing 410-420rwhp. Honestly, he drives the truck as easy as I did, only romps on it occasionally. I think he takes corners harder (as evidenced by front tire wear), but I don't blame him. With the Roush suspension, it handles great.

[Beaudee]

Mine is out as well where did you get the new pump?Thanks Beau I just got one from LFP 99 bucks

[WA 2 FST]

http://www.latemodelrestoration.com/ Not the absolute cheapest, but less than half of what the Ford dealership wanted. $99 is cheaper than what I paid... I paid $129. Simple, simple install ... Terry's help with size of the bracket bolts, etc was very nice.

[Beaudee]

I saw your post a while back and decided to check mine,did same thing tapped on it and worked a bit and quit.106,000 on mine,still drive it every day.Thanks :tu:

[L8 APEX]

LFP is a great source for all Lightning parts, it looks like they sell about everything now days. Being in Texas you usually get it next day.

[Beaudee]

LFP is a great source for all Lightning parts, it looks like they sell about everything now days. Being in Texas you usually get it next day.

I ordered it thurs and got it sat.,they where helpful when i had e-fan probs. also.Def. best place to get coil paks.That 2.3 whipple is lookin good to,sure have gone up in price though.

[L8 APEX]

I haven't looked recently. I know the first Whipple 'buy-in' was $50k in stock. So he was motivated to recoup that buy-in.

[Beaudee]

I haven't looked recently. I know the first Whipple 'buy-in' was $50k in stock. So he was motivated to recoup that buy-in.

They were a bit under 3000,now 4000.From what i see better to buy the whole truck with the Whipple or Kenny bell:icon_mrgreen: