The composite (plastic) intake manifold may crack near the thermostat housing and cause a coolant leak. Ford released an updated manifold that was reinforced to prevent a recurrence. No recall was issued for this problem but Ford did extend the warranty to seven years on some models from the date of purchase.
Car Problem Reports
Ford Explorer Plastic Intake Manifold May Crack Causing Coolant Leak
Ford Explorer Problem
Engines Affected: 4.0L V6, 4.0L V6 SOHC, 4.6L V8
Average Mileage: 121,800 mi (104,000 mi - 135,000 mi)
Visitor, 2002 Ford Explorer, 4.0L V6, 127,000 mi
Just got this same problem, coolant leaking by thermostat housing and manifold. Engine turned off while going down road, never realized coolant leaked out, luckily I was able to turn on a side street and stop the beast. Now I'm off to find the best price on a replacement for this inferior plastic manifold. If I only knew about the 2002's :-(
Visitor, 2002 Ford Explorer, 4.0L V6 SOHC, 133,000 mi
Problem: coolant leak from plastic thermostat housing, coolant seeping from center where two plastic halves are pressed together.
Solution: replaced housing (no way to repair plastic)
Visitor, 2002 Ford Explorer, 4.6L V8, 110,000 mi
Cracked manifold. Having it fixed but it is costing $1,100.
needs to be replaced
is this cover under warranty by ford?
Visitor, 2002 Ford Explorer, 4.0L V6 SOHC, 104,000 mi
Same thing happened to me. Went to the ford house and purchased a new one. tried to re seal it first but doesn't work. Save money and buy new.
Visitor, 2002 Ford Explorer, 4.6L V8
my plastic piece cracked on the thermostat housing causing a coolant leak..and the problem has not been fixed yet..i need some money 2 help gettn it fixed because u have 2 replace the whole intake..