Ford Explorer Problem Report

Ford Explorer Plastic Intake Manifold May Crack Causing Coolant Leak

(35 reports)

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.

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. -
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.. -
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) -
leaking coolant not going to the oil or on the ground but you can smell it when turn your car off -
coolant leak after driving for so many miles -
تسريب ماء المبرد من الكوع ومجموعة المكيف الساخن والقسام الموجود بالمجموعة... -
why would they make this part out of plastic???? -
Ford diagnosed issue when I went in for inspection...coolant thermostat housing needs replaced...leaking coolant. -
I had to replace my radiator for the fourth time because of the intake manifold cracking causing coolant leak. The last incident took place on Feb 5, 2015. -
I put new thermostat and housing and antifreeze still poolin on housing -
intake manifold needs replaced -
Purchased New Thermostat Housing w/ New Thermostat and New Temperture Sensor at AutoZone; installed myself and issued resolved. -
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!!! -
Happened to my car on 2013 -
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 :-( -
Cracked manifold. Having it fixed but it is costing $1,100. -
needs to be replaced is this cover under warranty by ford? -
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. -
Related Items:
The intake manifold O-ring gaskets commonly leak, causing stalling and poor idle quality; the C...
all my coolant leaked out so we thought it was a loose hose. but when we poured water into the...
A cosmetic crack may develop on the plastic liftgate trim panel. Ford has released a service pr...
will a gasket under a fuel rail on a 95 ford explorer cause a vacum leak
Heater - A/C blower is stuck on "defrost" regardless of what position the blower is set to. Fan...