Plastic Intake Manifold May Crack Causing Coolant Leak on Ford Explorer

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.

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Average mileage: 122,930 (10,000–235,000)
Engines affected: 4.0L V6, 4.0L V6 SOHC, 4.6L V8, 5.0L V8
14 model years affected: 1995, 1998, 1999, 2000, more2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010
116 people reported this problem
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Viewing 1 - 20 of 63 problem details
leaking coolant not going to the oil or on the ground but you can smell it when turn your car off
2008 Ford Explorer - 4.0L V6 SOHC 106,500 mi,
Just got my 2008 Explorer back from the Ford Dealership for routine LOF and overall inspection. Was told I need a new upper thermostat housing ($375 including labor) and a new radiator ($655 including labor) because of leaks. My research indicates the former causes the latter. I never saw coolant on the garage floor. This appears to be a common problem and would appreciate Ford taking responsibility for installing a PLASTIC housing in an area that produces much heat. Cheap part for Ford, but very expensive to replace for their loyal customers.
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..
Plastic thermostat housing leaking. Ford wants hundreds of dollars to replace it. So many problems with the 2002 Ford Explorers. Why would Ford use plastic!! Very angry.
2005 Ford Explorer - 4.6L V8 138,000 mi,
My Explorer overheated out of the blue one day. I filled it with coolant and when leaving for work the next day I noticed fluid that had leaked onto the ground. When my mechanic checked it out he said it was coming from the Intake Manifold area and it was the gasket. I bought a new gasket. When my mechanic got into the intake manifold he found out that part of the plastic was broken off. He put the gasket on and sealed it. After letting it sit a couple of days we started it up and it was STILL leaking. I have been without my vehicle now for 2 months because I don't know what to do!!!! The parts associate at the dealership where I purchased the new gasket said that there was a lawsuit regarding this problem but it only covered vehicles through 2001 and for a recall settlement we would have to get a new lawsuit started for vehicles 2002 and newer!!!
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)
1998 Ford Explorer 182,000 mi,
Water leaking from top piece of thermostat..& coolant jug keeps emptying cant hold water for a day..please help im not a mechanic...
2007 Ford Explorer - 4.0L V6 SOHC 73,500 mi,
Have had a coolant leak problem for over a year and the local Ford dealership was no help. All they wanted to do is leave the car with them for a few hours and maybe they could figure it out. Well don't have that kind of time or money since the car is no longer under warranty. Well at first thought water pump went out only to find out it was the thermostat housing has been the problem. If the local dealership was more helpful and if formed I would be out over $300 in cost so far. I really feel like Ford and their dealerships have let me down as a consumer of their products
2006 Ford Explorer - 4.6L V8 85,000 mi,
coolant leak after driving for so many miles
2004 Ford Explorer - 4.0L V6 SOHC 78,000 mi,
Replaced part, lucky to fix when crack was small.
2009 Ford Explorer - 4.0L V6 SOHC 100,500 mi,
Just noticed small amount of coolant sitting on the block. PLASTIC thermostat housing looks to be the source, seems to be above the intake. T-stat housing looks pretty easy to yank, pretty straight forward. Reading all the comments a pattern becomes very clear, FORD MOTOR COMPANY F$&ked up on this design and they've been sending that cheap crap out the door for at least 8 years. Everyone has the same issue from 02-09, and that's just what I've seen researching for 5 mins. Anyway, I'm gonna tear it out on my next day off, I'll let you know. Recall please!!! You cheap bastards...
1998 Ford Explorer - 4.0L V6 145,000 mi,
My 2006 Ford Explorer is leaking anti freeze on to my engine. The leak is coming out of a pice that I guess was sealed and now is not. How do I fix this?
1998 Ford Explorer - 4.0L V6 SOHC 109,220 mi,
Cracked housing tha caused the coolant to leak bad.
2005 Ford Explorer 130,000 mi,
Coolant leaking from plastic thermostat housing. Bought new one for 67$ took 1/2 hour to change. 5/16 socket and ratchet and a pair of channel locks. Quit your crying.
Coolant leaking from intake
2008 Ford Explorer - 4.0L V6 81,000 mi,
Bought a 2008 Explorer Sport-Trac in August of 2014. Was under the hood a couple of months ago, and noticed something resembling packing material sitting in the manifold area. Grabbed it with pliers and it turned out to be a wad of paper towel and trash. Talked to my mechanic, and we decided that the previous owner knew something was leaking a little. We talked about the fact that it was a known problem with the 4.0 engine. Decided to just wait and see. Flash forward to last Friday, and my Sport-Trac overheated on the way to work. Thermostat housing cracked. Bought part from Rock Auto -- Dorman, new and improved, over the MotorCraft part. Issue solved. $47 for the part, and $65 for labor.
2008 Ford Explorer 94,000 mi,
This is the second time in 6 months
2003 Ford Explorer 170,000 mi,
Change coolant once a week. Leaks occur in the manifold are where there are 3 prongs. Could not find the thing from all the autozone. All other cenues
2004 Ford Explorer 98,000 mi,
First of all this happened when we were on vacation lucky we have AAA roadside service. They took our Ford Explorer to a shop where they replaced the water thermostat intake manifold, with the same OEM plastic one. Since our old one failed after some 90,000 miles, we figured the plastic one will be okay. We finished our vacation in Las Vegas drove home to California with no problem and I believe the plastic housing will hold up although I'm thinking about buying the aluminum housing as we do use this vehicle for traveling, I do not want to get stuck away from home again. I think Ford makes a very good vehicle, but I don't like the way they hide problems from the customer. We had other problems with the Explorer such as the transmission, differential and the ever popular steering column shift falling off. Even if we didn't want this car he would now keep it because we have so much money tied up in repairs.
Loosing power and an order