Car Problem Reports

Ford Explorer Plastic Intake Manifold May Crack Causing Coolant Leak

Ford Explorer Problem
17 Reports
Me Too

Model Years Affected: 2002, 2005, 2006, 2007

Engines Affected: 4.0L V6, 4.0L V6 SOHC, 4.6L V8

Average Mileage: 108,777 mi (35,000 mi - 135,000 mi)


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.

  • Visitor, , 4.6L V8

    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.

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  • Visitor, , 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)

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  • Visitor, , 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..

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  • Visitor, , 115,000 mi

    Happened to my car on 2013

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  • Visitor, , 4.0L V6

    leaking coolant not going to the oil or on the ground but you can smell it when turn your car off

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  • Visitor, , 4.6L V8, 85,000 mi

    coolant leak after driving for so many miles

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  • Visitor, , 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 :-(

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  • Visitor, , 4.6L V8, 110,000 mi

    Cracked manifold. Having it fixed but it is costing $1,100.

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  • dtgiants, , 4.0L V6 SOHC, 135,000 mi

    needs to be replaced
    is this cover under warranty by ford?

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  • Visitor, , 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.

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