I opened up the tank this weekend to get a look at the float. I used my dremmel tool and cut a square hole right above the float. The float has a restrictor that keeps the float from going any higher than when the coolant is a half inch over the max line. There is about 1 inch of vertical movement available. Anything over a half inch above the max line is wasted coolant. The problem with my float is that it comes up to the top and then starts to sink a bit. Which makes sense in referance to why the light keeps coming on. The float was clean so that means over time the material that surrounds the magnet (which you can see) looses it's boyancy. So now I "know" I need a new coolant reservoir since there is no repairing this one. Anybody know the cheapest place to get Ford parts online? No sense in buying a used one since you'll end up with the same issue again.
Another thing worth noting is that the external switch has a dead spot in the center of it. I used a small magnet with my ohm meter and found a dead spot on the vertical shaft of the switch. You know the suppository looking thing. The switch's dead spot is about 3/4" starting in the middle of the vertical shaft. Basically the bottom of the switch is just not used. Bad design that all. Just a plain old bad design. I hope this sheds some light on the subject for you guys.
DaveNC
