2002 Explorer Coolant Leak
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Senior User
Joined: Nov 2001
Posts: 275
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From: Warner Robins, GA
2002 Explorer Coolant Leak
Greetings,
Son in law just bought a 2002 Explorer with the 4.0. Looks in pretty good shape and overall I don't think he got a bad deal. However....after a test drive I noticed an antifreeze smell. Got to poking around and it appears to be leaking directly below the thermostat housing and that whole manifold for lack of a better word. It's a bugger to get in there and really see what's leaking...doesn't appear to be any hoses but given the angle can't be really sure. I'm new to the Explorer and the 4.0. Before we jump in a start tearing things apart I thought I'd ask some of the more knowledgeable folks with the experience. Is this anything peculiar to the Explorer/4.0? A known part problem? Something far worse? Appreciate any insight.
RWT
Son in law just bought a 2002 Explorer with the 4.0. Looks in pretty good shape and overall I don't think he got a bad deal. However....after a test drive I noticed an antifreeze smell. Got to poking around and it appears to be leaking directly below the thermostat housing and that whole manifold for lack of a better word. It's a bugger to get in there and really see what's leaking...doesn't appear to be any hoses but given the angle can't be really sure. I'm new to the Explorer and the 4.0. Before we jump in a start tearing things apart I thought I'd ask some of the more knowledgeable folks with the experience. Is this anything peculiar to the Explorer/4.0? A known part problem? Something far worse? Appreciate any insight.
RWT
Mountain Pass
Joined: Jun 2012
Posts: 193
Likes: 34
From: Upstate, SC
Its common to have to replace the thermostat housing and orings. I normally do the upper and lower and install a new t.stat also. If the coolant temp sensor doesnt install tightly, replace it also.
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Senior User
Joined: Nov 2001
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From: Warner Robins, GA
Bingo! I did some more research and inspection and it is in fact the T-stat housing leaking. He's going to limp along with it till next Saturday then we'll tackle it. Doesn't look too hard. You would think somebody would have designed a better housing by now. I came across one Explorer owner who's replaced his three times before 80K miles. Does anybody know of one brand that holds up better than the FOMOCO part?
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Joined: Feb 2011
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From: FT. Rucker AL
I just did this job over the weekend. It takes some time and just go slow. It is doable. Don't be in a rush.
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Joined: Apr 2011
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Bingo! I did some more research and inspection and it is in fact the T-stat housing leaking. He's going to limp along with it till next Saturday then we'll tackle it. Doesn't look too hard. You would think somebody would have designed a better housing by now. I came across one Explorer owner who's replaced his three times before 80K miles. Does anybody know of one brand that holds up better than the FOMOCO part?
use existing upper in the mean time. Seller is offering the lower separately @ $149 including all gaskets. I have NO affiliation with this seller, just FYI. GL
05 10 Mustang 4 0 V6 Metal Thermostat Housing | eBay
http://www.explorerforum.com/forums/...d.php?t=362922
Cross-Country
Joined: Dec 2009
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See if this will help
Quick scanning as to help .... not the best
I bought a housing from Parts Geek
85331 | Partsgeek.com
Wished I knew about the metal one...well the last one last over 10 years so if this one last 1/2 as long I will be happy.
BTW the EGR tube id just pressed into the air intake with a O ring and pulling hard will remove it. Get a gasket set for the intake...around $17
Quick scanning as to help .... not the best
I bought a housing from Parts Geek
85331 | Partsgeek.com
Wished I knew about the metal one...well the last one last over 10 years so if this one last 1/2 as long I will be happy.
BTW the EGR tube id just pressed into the air intake with a O ring and pulling hard will remove it. Get a gasket set for the intake...around $17
Senior User
Joined: Feb 2011
Posts: 421
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From: FT. Rucker AL
I replaced mine. Its an 01 however I am still having an issue with the temp sensor not working right. I did replace both of them with ones from local auto parts store. O rielly's and for some reason the temp never gets above the lower C line. I will have to play around with it. Take your time with replacing it. I know on mine it was about a 7 hr project and a few curse words.
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