Car Problem Reports

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

Ford Explorer Sport Trac Problem
42 Reports
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Model Years Affected: 2001, 2002, 2003, 2004, 2005, 2007

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

Average Mileage: 116,763 mi (11,800 mi - 268,000 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, , 95,000 mi

    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.

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  • Visitor, , 121,000 mi

    coolant usage with no apparant/visable leak.

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  • Visitor, , 95,000 mi

    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

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  • Visitor, , 110,000 mi

    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.

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  • 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.

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  • Visitor, , 174,000 mi

    Just replaced the plastic manifold due to a leak. Cost $800. Yikes!

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  • Visitor, , 11,800 mi

    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.

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  • Visitor, , 99,890 mi

    Engine overheating/loss of coolant. Housing split. Pressure test confirmed. Replacing upper & lower housing&thermostat.

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  • Visitor, , 169,500 mi

    Problem: coolent leaking. Started removing parts to get to the water pump. Was advised to check the intake manifold housing area. Seems like this maybe the problem. Having mobile machanic come to check it out to be sure of the problem. Will know something definately later this evening/tonight.

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  • Visitor, , 4.6L V8, 81,500 mi

    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.

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