Hello
2006 Explorer EB with 170,000 miles on it, original trans and engine. The only problem this Explorer has is it has been leaking from upper radiator hose and or at the thermostat housing. I have replace the radiator twice and the ome thermostat housing once. Other then this it has been trouble free.

Who has replaced there ome thermostat housing with the ALUMINUM THERMOSTAT HOUSING. If so, did it help,
and what kind of hose clamps work the best.

 

Greetings,

I know its been a year, but maybe this is still a relevant issue for you. We have a 2005 Explorer with the 4.0L V-6. I have replaced the leaky nylon water outlet/thermostat housing three times since we bought the vehicle in 2006. The last one only made it 3 years before busting a seam and leaking coolant all over the top of the block. I was by now quite disgusted with the leaks and the poor design. Why weren't these designed in metal from the get-go, I'll never know. Rather than go down to the national chain auto parts store on the corner for yet another one made from black synthetic material at almost $100 each, I did some research. After searching a couple of Explorer forums, I found that there are a couple of suppliers that have them in cast aluminum. I located an aluminum replacement from a major on-line auto parts supplier ($44+/- and I think the shipping might have been free) I had a choice of one or two sensor ports. Mine has one temp sensor. Seems all the replacements come with blank plugs inserted so the one with two ports will work if you have but one sensor like mine. It looks like a clean, well-made design and was a spot-on direct replacement. I re-used all the hoses and clamps. That was earlier this month and so far, no leaks.

Regards, Lewis

 

Here's a write up I did on it. https://www.ford-trucks.com/forums/1...-assembly.html

 

Appreciate all posts on v6~4.0L~SOHC Plastic ThermoStat Housing & fixes.
Swapped my 2001 Ex Sport Trac to an aluminum ThermoStat Housing in 2019Aug.
No leaks as of now 2020Mar & ~5K more miles, knock on plastic!
My write up & pics:
http://2001fordexplorersporttrac.fan...moStat_Housing