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Ford Explorer Plastic Intake Manifold May Crack Causing Coolant Leak

 
Ford Explorer Problem
30 Reports
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Model Years Affected: 2002, 2003, 2005, 2006, 2007, 2008

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

Average Mileage: 115,833 mi (11,000 mi - 180,000 mi)

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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

    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, , 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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  • MTkitchn, , 4.0L V6 SOHC, 106,500 mi
     Rookie

    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.

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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, , 4.0L 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, 85,000 mi

    coolant leak after driving for so many miles

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  • Ghost Rider 15, , 4.0L V6 SOHC, 120,000 mi
     Rookie

    I had to replace my radiator for the fourth time because of the intake manifold cracking causing coolant leak. The last incident took place on Feb 5, 2015.

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  • jojoba, , 4.0L V6, 179,000 mi
     Rookie

    I put new thermostat and housing and antifreeze still poolin on housing

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  • Visitor, , 4.6L V8, 180,000 mi

    intake manifold needs replaced

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  • Visitor, , 4.0L V6, 114,000 mi

    Purchased New Thermostat Housing w/ New Thermostat and New Temperture Sensor at AutoZone; installed myself and issued resolved.

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