The outlets changed from the early design (left) to the late design (right) for the '94 MY. Here are a few part numbers for the late design:
The 3.8L’s may have stuck with the splayed design. It’s been too long for me to recall.I never knew this. If you look under 1997 and 3.8 it shows the split style but the 4.6 shows the correct one. I assumed they would be the same so I never looked.
For what it's worth, official Ford guidance (via a TSB) was not to ground. We had a thread about that not too long ago.I am going to run a ground strap to it either way.
Exactly. My genuine theory is they were concerned technicians would fasten the other end of the wire to a poor point contact that wouldn’t stop the electrolysis, so rather than risking a return visit from the same customer armed with a complaint their core failed despite their touted repair, walking back the TSB on paper all gets the stealership off the hook, and rake in the hours for another heater core jobIf you ground ALL parts of the cooling system together it will not corrode. Block, radiator core, and heater core. The radiator core is not grounded in our car except by accident, unless you do it yourself. That's what most people miss.
Or just wrap electrical tape around the copper strands and hose outlet and then put the stainless clamp over the tape to tighten it together, then the stainless clamp won’t react with eitherAs long as you don't drill thru a tube, there's no danger. A copper wire touching a stainless ho se clamp is going to corrode in winter driving. A good ring terminal is tin/lead dipped, or at least, the 30 yo box I have is. It helps a lot. Galvanic corrosion is a *, lol.
To eliminate it, requires extreme measures. So, just inspect and replace as necessary. If you replace the coolant every two years, you'll never have a problem, three years is too long, from personal experience. If it turns brown, it has boiled, and needs replaced.
Here's the table; the further apart right-left, the higher the potential. To eliminate the corrosion, you have to remove the voltage, or the electrolye. Rainwater is mildly conductive, but you add salt, you have an unwanted battery.