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: 145,522 (1,007–2,120,000)
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
107 people reported this problem
65 people shared problem details
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
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
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- 4.6L 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.
2008 Ford Explorer- 4.0L V6
I just purchased for explore four days ago and now the plastic manifold cover is sprain antifreeze back on the engine. Looks like an easy fix I will update.
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)
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!!!
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
2004 Ford Explorer- 4.0L V6 SOHC78,000
Replaced part, lucky to fix when crack was small.
2006 Ford Explorer- 4.6L V885,000
coolant leak after driving for so many miles
2005 Ford Explorer- 4.0L V6160,000
You could smell coolant after you shut the vehicle off.. a few days later, it started a steady drip of coolant... wtf
1998 Ford Explorer- 4.0L V6 SOHC
obviously cracked and poors coolent out of engine
2008 Ford Explorer- 4.0L V6128,000
Plastic housing is cracked. Antifreeze and water leaking. Mechanic wants $500 to fix it. Who puts plastic above the engine where it gets heated??? Ford needs to step up!!!!
1998 Ford Explorer- 4.0L V6 SOHC109,220
Cracked housing tha caused the coolant to leak bad.
2008 Ford Explorer- 4.0L V6 SOHC160,640
I had noticed just a few weeks ago that my 2008 Ford Explorer was driving very sluggish.Just on last week I checked my coolant system & found that it was bone dry empty. I didn't see any leakage at all & since filling the tank up w/coolant I thought that I had resolved the problem.Well,Apparently not...Just on today I took my truck in to the dealership for a regular oil change & yet again now for the (5th) time in over a 2year period I discovered that the entire thermostat housing component needs to be replaced. I spoke w/the Ford Dealership mechanic & explained to him that this is ridiculous because every single time-it appears that I bring my Explorer in there's always an issue w/the thermostat housing. Ford certainly has away of knowing how to get money out of there customer's & the know that these parts are Dirt Cheap & will only last for up to so many amount of miles.Certainly glad that I'm covered under the warranty on this one,otherwise I would be paying out close to $700+ dollars & that's ridiculously insane.
2008 Ford Explorer- 4.0L V681,000
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- 4.0L V6
Coolant leaking from intake
2006 Ford Explorer- 4.0L V6138,560
Water leak at thermostat started looking into repair. Under pressure found two small leaks in intake gasket.
2010 Ford Explorer11,500
I have antifreeze leaking I change. The water pump
1998 Ford Explorer- 4.0L V6 SOHC131,000
Crack in housing, upper and lower housing replaced
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