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.Google+
Car Problem Reports
Ford Explorer Sport Trac Plastic Intake Manifold May Crack Causing Coolant Leak
Ford Explorer Sport Trac Problem
Engines Affected: 4.0L V6 SOHC, 4.6L V8
Average Mileage: 117,113 mi (42,000 mi - 229,000 mi)
Visitor, 2003 Ford Explorer Sport Trac, 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.
Visitor, 2005 Ford Explorer Sport Trac
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.
Visitor, 2005 Ford Explorer Sport Trac, 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
Visitor, 2005 Ford Explorer Sport Trac, 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.
Visitor, 2005 Ford Explorer Sport Trac, 121,000 mi
coolant usage with no apparant/visable leak.
same exact problem
Visitor, 2002 Ford Explorer Sport Trac, 174,000 mi
Just replaced the plastic manifold due to a leak. Cost $800. Yikes!
Visitor, 2005 Ford Explorer Sport Trac, 148,000 mi
Leaking water need to replace
Visitor, 2004 Ford Explorer Sport Trac, 60,000 mi
same as described above
So that's where the mystery coolant leak is coming from!