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.
Plastic Intake Manifold May Crack Causing Coolant Leak on Ford Explorer Sport Trac
Average mileage: 122,419 (11,800–268,000)
Engines affected: 4.0L V6, 4.0L V6 SOHC, 4.6L V8
74 people reported this problem
41 people shared problem details
2007 Ford Explorer Sport Trac- 4.6L V881,500Visitor
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.
2003 Ford Explorer Sport Trac95,000Visitor
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.
2005 Ford Explorer Sport Trac121,000Visitor
coolant usage with no apparant/visable leak.
2005 Ford Explorer Sport Trac110,000Visitor
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.
2003 Ford Explorer Sport Trac99,890Visitor
Engine overheating/loss of coolant. Housing split. Pressure test confirmed. Replacing upper & lower housing&thermostat.
2008 Ford Explorer Sport Trac145,000Visitor
Leak at back of thermostat housing.
2005 Ford Explorer Sport Trac95,000Visitor
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.
2003 Ford Explorer Sport Trac88,000Visitor
plastic thermostat housing cracked and created a leak overheating engine.
2005 Ford Explorer Sport Trac11,800Visitor
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.
2002 Ford Explorer Sport Trac174,000Visitor
Just replaced the plastic manifold due to a leak. Cost $800. Yikes!
2002 Ford Explorer Sport Trac118,500Visitor
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. :-(
Smell of burning coolant, no visible traces. reservoir empties in two weeks.
Plastic housing for themostat cracked ahd to be replaced
2003 Ford Explorer Sport Trac121,000Visitor
White smoking coming from underneath intake manifold? Smells like burning coolant, was reading previous post as well as talked to my father and he said it could be the thermostat or intake gasket what do you guys think?
2004 Ford Explorer Sport Trac170,000Visitor
I had to get a new thermostat!
2002 Ford Explorer Sport Trac100,000Visitor
I haven't fixed it yet but the thermostat housing is cracked and had drained the coolant and created overheating
2003 Ford Explorer Sport Trac208,975Visitor
Leaking coolant. Haven't fixed. Not driving truck. Can't afford the parts to fix it. Will wait till spring 2016.
2005 Ford Explorer Sport Trac87,000Visitor
Observed smoking from the engine on the freeway. Ford dealership diagnosed issue as cracked thermostat housing. Cost to repair is $711.
2002 Ford Explorer Sport Trac158,000Visitor
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.
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