wiper washer sprayer issues.

[shenrie]

I had inquired about same issue in my build thread and this was posted. im reposting here for future reference of anyone else having the similar issues. again, awesome writeup JWA!

Originally Posted by JWA

This is something I wrote for FTE detailing replacement of the washer reservoir & pump assembly. Hope it doesn't include too much info not relative to your particular case Shrenie:

My '03 E250 had developed a leak evident only after filling it to a certain level, excess amount above the leak running out onto the ground. Even though mine still held some washer solution and pumped adequately stopping the leak was the goal--hate not having a full tank of washer solution!

This is what caused the leak, filler tube connection to the reservoir:



My speculation is rather severe rusting away of the right side inner fender structure allowed the washer fluid's weight and normal driving to pull it downward:



The washer reservoir is located under the battery. Once its out the battery tray is next. so that needs removed first then the battery tray. There are various type battery hold down clamps, mine was the lower type that fits into a recess at the bottom of the battery case. Battery tray removal should be pretty much the same from model year '92 to at least 2008, perhaps beyond too.
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Reservoir as installed under the battery tray:



Remove the filler neck where it attaches to the upper cowl panel:



Easiest access to left side bolt:



At this point there would a right side nut to remove but the inner fender rust damage eliminated this step for me.

The reservoir lifts up and follows the inner fender's slope which moves it backward too. Right side mounting tab cannot easily clear the harness wiring:



I removed and separated this connector as it seemed the best way to remove the reservoir:







Side-by-side view of new and old reservoirs, showing a few improvements I think. The new style hose is not only shorter overall but is secured and kept flush to the reservoir body; older style used longer hose, securing clips mounted along its length.



Re-connect the pump connector, a bit of dielectric grease can't hurt:



Re-install new reservoir, notice the highlighted area again. Since the wiring harnesses are moved aside it almost falls right into place



From here I wanted to better secure the reservoir so this didn't happen again. I cobbled a solution of sorts together using T-shaped mending plates typically used around the home, a few over-sized fender washers, U nut and 1/4-20 bolt:



It ain't pretty but it works----so far!

Original right-side mounting tab and stud, rusted away:





Just to be safe a cable tie was used:



After re-installing the battery tray and battery filled the leak-free reservoir all the way to the top --dry as a bone. I do notice the new pump and possibly its shorter hose run seems to squirt a better pattern, more completely covering the windshield. It wasn't horrible before, just better now.

Part numbers used or applicable, all Ford OEM:

Reservoir..............8C2Z-17618-A
Battery Tray..........3C2Z-10732-AA
^^ Bolts...............N606688-S2
Hold Down............6C2Z-10756-A

Feel free to ask any questions, add your own suggestions or comment---anything that helps the next guy!