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Explorer, Sport Trac, Mountaineer & Aviator 1991-1994, 1995-2001, 2002-2005, 2006-2010 Ford Explorer

97 Explorer- Replacing bypass hose - HELP!!!

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Old Jan 20, 2016 | 03:15 PM
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drummertroy
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This is an old topic but still a current issue!..
I found no other way to do this the "Right" way without looking up info on removing/replacing the thermostat housing. Most likely if your Factory bypass hose blew out (mine did), then you will likely have a corroded housing etc. if you're going to replace the hose, you might as well do the Thermostat at a minimum, perhaps the housing if the plastic is corroded (mine was and as you see in the links for more info..one of the 3 tabs that the housing uses to fit onto the intake/block had broken and the gasket was toast.. see 2nd link for that info)

Watch this video..I think I could safely do this in 3-4 hours all in.
You'll need a long handled 8mm Ratchet wrench, patience and overall after knowing how to do this once (hope you never have to again)..you'll be able to do on your own without help.

All of this for an 8$ hose... bad design ford!

Watch this vid:

READ THIS!! Very detailed and helped me all the way thru.. good tips here that I used (as in when putting in the sensors, plug in first, then slight them in at an angle until they seat in..you'll see what this means when you get there)
Also, I was able to REINSTALL the Housing COMPLETE with no issues (the 2nd link took the top off and installed that way.. perhaps easier? but you can do without taking apart..up to you)
This link is the bible!: How To Replace the Upper and Lower Thermostat Housing on a Ford 4.0L V6 SOHC Engine
 
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