Plastic Intake Manifold May Crack Causing Coolant Leak on Ford Explorer Sport Trac

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: 117,354 (11,800–268,000)
Engines affected: 4.0L V6, 4.0L V6 SOHC, 4.6L V8
7 model years affected: 2001, 2002, 2003, 2004, more2005, 2007, 2008
67 people reported this problem
36 people shared problem details
I just got a a word that the leak coming out of my thermostat originated from my intake manifold and it going to cost $700. Part is exclusive Delear part. They need a recall.
2007 Ford Explorer Sport Trac- 4.6L V881,500
My 2007 Explorer Limited is using atifreeze very faast and it is niot not showing up on the garage floor. It does not seem to be the heater core, because there is no coolant smoell in cab and no residue coming out of dedfroster/heater. I am looking for a way to check the plastic intake manifold for leakage.
coolant usage with no apparant/visable leak.
craked intake under the thermostat housing. its not fixed. i wasn't the original owner. so ford told me to go away. they can't help me. but i've been driving with it like this for a while. all i can do is pray i don't break down in the middle of no where with my kids. but hey. what does ford care bout that. tey got tere money worth.
Engine overheating/loss of coolant. Housing split. Pressure test confirmed. Replacing upper & lower housing&thermostat.
I went on vacation my 2005 sport trac broke down, steam coming out. Had to have it towed, slept in a truck stop on a friday night in no name Giorgia. 36 hours later and $500 I was back on road. Came back home from vacation and the exact same thing happen again. I got screwed by Ford and the mechanics
Overheated with steam coming from under hood. I thought that it was the thermostat housing, but after taking the cover off found that it wasn't cracked and the leak coming from beneath. I was under the assumption that this was still the bottom half of the thermostat housing, but it is apparent from what I'm reading that it is the gasket for the intake housing. Difficult to get to, had vehicle towed to mechanic for repairs. Now awaiting the verdict. I'm sure that I'll be coaxed into the notion that it is the entire intake manifold.$$$$$ What can I say,...gotta have my transportation.
Dam they have it close with the 115,000 miles. Mine went while out to dinner. Tried to make in home filling up at autozone but gets to hot. $70 for tow to dealer, see what cost monday.
Just replaced the plastic manifold due to a leak. Cost $800. Yikes!
Leak at back of thermostat housing.
plastic thermostat housing cracked and created a leak overheating engine.
Observed smoking from the engine on the freeway. Ford dealership diagnosed issue as cracked thermostat housing. Cost to repair is $711.
2002 Sport Trac overheated while driving on the interstate. Found a crack in plastic thermostat housing and replaced it and refilled coolant. A week later it overheated again and when I checked the coolant it was very low so I refilled and now ever time I check it its low. It is still losing the coolant but I can't see any visible leak.
4.0 liter Engine overheated and I found a crack in the thermostat housing and replace it. Still losing coolant but cannot see any visible leaks
I have a 2002 Ford Explorer with 4.6L V-8 engine. I noticed loss of coolant but no apparent leak. I saw some coolant on top of engine block after driving. I pressured tested the cooling system and saw coolant leak at base of lower metal thermostat housing where it meets the black plastic intake manifold. Since the lower metal thermostat housing is part of the black plastic intake manifold, it looks like the entire black plastic intake manifold will need to be replaced. :-(
T truck over heated found lower thermostat housing cracked around seam. Needle pictures to order a new one..
E150 would heat up when idleing for a short period of time. (waiting in line at bank, drive thru, etc.) Mechanic found a crack in the plastic manifold. $841.00 later it was fixed. Thank God it was discovered 4 days before a trip to Las Vegas (where the temp was 104 today) was to start. Leaving in two days hope the repair was complete hate to overheat in the desert. Taking lots of water just in case.....
2008 Ford Explorer Sport Trac- 4.6L V888,000
Slow leak at thermostat drains onto top of engine block and evaporates. No visual confirmation, but tell tale smell when parked in garage with hot engine... Cannot find much other information about replacement with other than OEM part:(
Plastic housing for themostat cracked ahd to be replaced
Same issue with the leak by the thermostat housing that has been reported on the sport track.I have a 2002 ford ranger 4.0 liter Plastic Intake Manifold May Crack Causing Coolant Leak
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