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: 118,974 (11,800–268,000)
Engines affected: 4.0L V6, 4.0L V6 SOHC, 4.6L V8
52 people reported this problem
32 people shared problem details
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 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.
2005 Ford Explorer Sport Trac121,000Visitor
coolant usage with no apparant/visable leak.
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
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.
2002 Ford Explorer Sport Trac174,000Visitor
Just replaced the plastic manifold due to a leak. Cost $800. Yikes!
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.
2003 Ford Explorer Sport Trac99,890Visitor
Engine overheating/loss of coolant. Housing split. Pressure test confirmed. Replacing upper & lower housing&thermostat.
2002 Ford Explorer Sport Trac221,000Visitor
I noticed low coolant an like could smell it.l noticed coolant around thermostat housing. Then I seen coolant coming out of the front left head . Unit does not overheat and there is no water in the oil.I started tearing unit down. Looking for best route to take.
2005 Ford Explorer Sport Trac140,000Visitor
T truck over heated found lower thermostat housing cracked around seam. Needle pictures to order a new one..
2003 Ford Explorer Sport Trac170,000Visitor
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 V888,000Visitor
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
2002 Ford Explorer Sport Trac13,900Visitor
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
2003 Ford Explorer Sport Trac169,500Visitor
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.
2007 Ford Explorer Sport Trac- 4.0L V663,000Visitor
Leaking fluid from plastic manifold
$1700 repair for this exact problem!
2002 Ford Explorer Sport Trac268,000Visitor
Leaking near the thermostat housing
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