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: 118,695 (1,007–235,000)
Engines affected: 4.0L V6, 4.0L V6 SOHC, 4.6L V8, 5.0L V8
13 model years affected: 1998, 1999, 2000, 2001, more2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010
75 people reported this problem
41 people shared problem details
2008 Ford Explorer- 4.0L V6 SOHC106,500
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.
2002 Ford Explorer- 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.
2005 Ford Explorer- 4.0L V6
leaking coolant not going to the oil or on the ground but you can smell it when turn your car off
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..
2002 Ford Explorer- 4.0L V6 SOHC133,000
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)
2006 Ford Explorer- 4.6L V885,000
coolant leak after driving for so many miles
2004 Ford Explorer- 4.0L V6 SOHC78,000
Replaced part, lucky to fix when crack was small.
2007 Ford Explorer- 4.0L V6 SOHC73,500
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
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!!!
1998 Ford Explorer- 4.0L V6 SOHC109,220
Cracked housing tha caused the coolant to leak bad.
2006 Ford Explorer- 4.0L V6 SOHC128,000
It's leaking something. Haven't taken to find out what is wrong
2002 Ford Explorer- 4.0L V6180,967
I went to the store everything was running perfect come out crank it and it was chugging and jerking so I pulled over had no water so I filled it up can home mean while it was still acting up. Hubby noticed where it was leaking from was back side ove thermostat housing. Changed it and has not ran right since so it has been parked. Will never buy another Ford.
2000 Ford Explorer- 5.0L V8
Leaking antifreeze
2009 Ford Explorer- 4.0L V684,952
leaking around thermostat housing lower. I kept putting it off and it got worse. Mileage is now 107102. Leaking all around now and coolant storage unit is empty.
2001 Ford Explorer- 4.0L V6167,000
My radiator manifold housing made it 167,000 miles, then died at once with a small leak, no coolant puddle in my garage, then a huge one with overheating & steam everywhere from under the hood. I finally used my 20 years of towing insurance, I know better than to drive an overheated engine because I tried making ito the shop I've seized one before. The repair shop mechanic he was "forced" to go the dealer for a higher priced replacement housing for my Explorer Sport because that was "unique to the '01 model," maybe true but I think he soaked me. It came to $880 all told & I smell burnt coolant under the hood but more disturbing is the missing throttle. Not going back there though even to tune it up, I can't trust that mechanic anymore.
2003 Ford Explorer- 4.0L V6111,000
Cracked thermostat housing water and green fluid leaked all over drive way under car.
2004 Ford Explorer- 5.0L V8130,000
Constant leaking we were told its the water pump and thermostat that need a replacement
Took the Ford in for a oil change was told that the Thermostat housing was cracked and needed to be changed out quoted me 150.00 for labor 375.00 for parts and labor. I think that I will just go to O Reilly's auto parts and just change out the parts myself it will be cheaper and at least I know that it will be done right. I think that Ford should put out a recall for this part seeming how there are so many parts on here that are showing cracking and wear and tear before the time shown on the parts website. These parts should be good at least until 100,000 miles and from all the comments it is showing that most are going out at 80K.
2004 Ford Explorer- 4.6L V8172,000
My 2004 Eddie bower edition v8 explorer just all of a sudden overheated no warning thought it was upper house turns out a cracked intake you would think when you spend almost 40 thousand on a vehicle and the company knows its a problem they knew about they would fix it by recall since its not only a few trucks but the majority of them I believe when I have this fixed it will be sold and I will never purchase another ford again !!!!!!! Its bad when imports are more dependable than American Mar vehicles. My next purchase will be a Toyota truck at least they are better built than ford
2004 Ford Explorer- 4.6L V8190,802
Leaking but not overheating
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