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HAVE THE COOLING SYSTEM PRESSURE CHECKED. THIS WILL LET YOU KNOW FOR SURE WHERE THE LEAK IS. THESE HAVE A PLASTIC INTAKE THAT OFTEN CRACKS BELOW THE THERMOSTAT HOUSING ON THE BOTTOM
without taking it off its difficult to say but if its a plastic housing then renew it as these plastic housings to tend to crack with age and dont forget the antifreeze
The all-black-plastic manifolds are susceptible to cracking. You should inspect the manifold carefully for cracks, but it might be hard to see if it is cracked underneath. You could try replacing just the thermostat housing, but if you still get leaks, you will probably need to replace the manifold as well. Ford recalled some fleet cars for this issue, but not all cars affected.
You may have to remove the thermostqat housing and replace the O ring that is the seal. Otherwise the housing is cracked and needs to be replaced or repaired with an epoxy patch. Hope this assists you.
1. drain coolant
2. remove engine cover
3. remove the 2 bolts from water hose connection (upper rad hose connecting to)
4. remove o-ring and thermostat
5. repeat in reverse order
The O-ring gets placed on top of the thermostat. Ford uses a two-piece hard plastic housing (non metal) and if you insert the O-ring before the thermostat then it will leak. That leak might cause some to over-tighten the bolts holding the housing together and leading to cracking of the housing. (The upper housing costs about $45 and lower about $65.) There is no gasket between the two housings.The thermostat is designed to allow the O-ring to fit snugly.
Changing the thermostat on this engine is veryeasy. It's only necessary to drain a small amount of coolant from the engine to start the repair.
I just had this happen to me we had to replaced the whole thermostat housing because its plastic it cracked no explanation why but the crack was in the very back leaking down towards the waterpump .
I just had the same problem. Ford design the intake manifold with plastic water crossover which cracks. The coolant will leak onto the top of the block and and then down the back of the engine. This intake design is a known defect and was ocvered under by Ford for 7 years past the date of mfg. The crack either is in the crossover or the thermostat housing. I happed on this when I found the same leak and traced it back to the thermostat housing. I changed the thermostat, but it leaked worse. You can pickup a aftermarket for $200 and it's about 4-6 hr job to replace.
IF YOU LOOK UNDER THE CAR, NEAR THE ALTERNATOR YOU WILL SEE A PLASTIC HOUSING WITH 2 PIPES LEADING ONTO IT. THE THERMOSTAT SITS IN THAT. JUST BE CAREFUL YOU DONT SNAP THE BOLTS WHEN REMOVING THE HOUSING.THE HOUSING ITSELF CAN BECOME WARPED OR CRACKED AND LEAK FLUID, A COMMON PROBLEM WITH THE FOCUS. THE HOUSING COSTS AROUND £15 AND A THERMOSTAT ABOUT £6. GOOD LUCK.
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