Electrolysis detroying heater cores and radiators!!

OregonFordlover · 10-02-2008, 10:59 PM

I have a 1999 Expedition with only 95,000 miles. I'm the only owner and have meticulous maintenance records for it. Here's the problem: 3/06 my heater core failed due to excessive electrolysis. (at only 68k miles) Just 56 days later, it failed again and again 12/06. I paid for the first and the other 2 were under warranty. They followed all TSB's (grounding strap, flushing, etc) then finally put in a copper one. They said the electrolysis eats at soft metals like heater cores. It likes radiators, too, because one month later (1/07) the radiator failed. Antifreeze everywhere!! We lost the "it's the same problem/different part" argument and paid the bill. 11/07: Happy Thanksgiving! Another new radiator. Yesterday it failed again. Even though it had only been 10 months, the original repair was 1/07 so this one was our dime!! The 12 month/12,000 warranty should start over everytime the repair is done, but not so. 3 heater cores and 3 radiators in 2 1/2 years and now they say the only way to completely stop this problem is drop in a new engine for 6k because the metals in engine are now like a battery. FORD has no clue what causes this and no plans for recall. Am I the only one with this problem? Extremely frustrated!! I don't feel I should have had to pay for all this. Love my truck and don't want a new one. Any sensible advice?

TBIRD430 · 10-03-2008, 02:30 PM

I know Ford makes an additive you simply pour in with the coolant for the desiel trucks. The Motorcraft PN# was FW-16, its now like BC4A, VC4B or something like that. It is used to stop porosity, the eating away of aluminum parts, and to keep the Electrolysis levels down. There are even Motorcraft test strips available so owners can check the protection level they have in the cooling system with this additive. Maybe this is just what you need "OregonFordlover"?

mark v · 10-03-2008, 06:37 PM

You never mentioned how often the coolant was flushed with your perfect maintenance?

Coolant is one of the most neglected things done. Also by adding tap water or water that was not distilled will speed up electrolysis along with low grade antifreeze.

OregonFordlover · 10-04-2008, 02:14 PM

Thanks, Mark. We did all maintenance per owner's manual and dealer recommendation. Same dealership for all the work. We've NEVER put water in it. Hopefully, the dealership didn't use low grade antifreeze. I really want to know if this is a widespread problem with other Ford owners or if I'm just the unlucky one.

mark v · 10-04-2008, 08:12 PM

I have never heard of this issue before. I would get a second opinion from another dealer.

BroncoJoe19 · 10-04-2008, 08:33 PM

This was an interesting read.
_Electrolysis Contamination

ON our boats we always had a zinc plate attached to exposed metal such as the rudder and drive shaft, so that electrolysis would affect the zinc, and not the important parts.

This site offers a magnesium radiator cap based on the same principal.

goon · 10-04-2008, 09:53 PM

test strips only test ph level if you need to check it for Electrolysis try using a digital multimeter wwhat you want to do is put on dcvolts 20 should work put one end in the coolant bottle or rad. and the other lead on the negative battery post. you want to see a reading of .2 volts or less. and make sure the ground straps are okay.

OregonFordlover · 10-05-2008, 09:15 PM

Thank You, BroncoJoe!! The "electrolysis contamination" link you gave was amazing. I read it and then researched magnesium radiator caps. Found out that FORD uses them in high performance racing cars but won't put them in passenger cars! Proof they know how to control the problem yet chose not too, at consumer expense. I am so angry! I swear there is a conspiracy going on. My next call is directly to FORD (I'm done with the dealer). Thank you! Thank you!

TBIRD430 · 10-06-2008, 09:13 AM

Okay. Well good luck & keep us posted.

fordfred · 10-15-2008, 03:00 PM

Quote:

Originally Posted by OregonFordlover

I have a 1999 Expedition with only 95,000 miles. I'm the only owner and have meticulous maintenance records for it. Here's the problem: 3/06 my heater core failed due to excessive electrolysis. (at only 68k miles) Just 56 days later, it failed again and again 12/06. I paid for the first and the other 2 were under warranty. They followed all TSB's (grounding strap, flushing, etc) then finally put in a copper one. They said the electrolysis eats at soft metals like heater cores. It likes radiators, too, because one month later (1/07) the radiator failed. Antifreeze everywhere!! We lost the "it's the same problem/different part" argument and paid the bill. 11/07: Happy Thanksgiving! Another new radiator. Yesterday it failed again. Even though it had only been 10 months, the original repair was 1/07 so this one was our dime!! The 12 month/12,000 warranty should start over everytime the repair is done, but not so. 3 heater cores and 3 radiators in 2 1/2 years and now they say the only way to completely stop this problem is drop in a new engine for 6k because the metals in engine are now like a battery. FORD has no clue what causes this and no plans for recall. Am I the only one with this problem? Extremely frustrated!! I don't feel I should have had to pay for all this. Love my truck and don't want a new one. Any sensible advice?

Hey I have had the same problem,3 rads,truck in shop as I speak # 3 heater core. I was in the trucking bus years ago and we had an additive that we used in our coolant that the engine manufacter recommended to retard or prevent electrolysis, it was sold by cummins engine and it was called dca additive i am going to try to find some for the new heater core