Changes: Engine Coolant ThermoStat

Latest revision as of 14:28, 23 May 2022

In early 2019 & 19+ years, the FactoryOE ThermoStat Housing on my 2001 Ford ExplorerSportTrac started
to leak per the pics below; at first just an irritation, this leak steadily grew much worse. Under the Throttle
on the V6~4.0L~SOHC engines TopFront in several 1997~2012 models, the FactoryOE coolant ThermoStat
Housing is made of PPS Plastic, with SeparatelyMolded Lower+Upper parts joined using a Heated\Glued
flange seam, notorious for leaking. My housing leaked into the "Cave" atop the engine under the Manifold,
creating a smelly Coolant+Grime swamp. Various Ford part#s for the housings have similar LowerBodies;
UpperBodies vary with 1 or 2 ThreadMt or ClipMt Sensors; TopCovers vary with RightHi\RightLo\ForeWard
routed RadiatorHoses. After concluding any new Plastic replacement will want to leak as the factory part
leaked, I upgraded to an Aluminum TStat Housing 2019Aug; no leaks as of 2022May & another 10k+ miles.

Minimal skill+patience, several hours, a level shop floor & the basic items below are needed for this repair:

* Hex+Torx SocketSet +DriverSet +Rachets +Adaptors +WrenchSet +SwivelExtensions

* ChannelLockPliers +NeedleNosePliers +ViceGripPliers

* WetVac +AirCompressor +Rags +Gloves +DrainPan +DisposalContainers +AbsorbantLitter

* HiTemp RTVSealant 750f PermaTex# 27038.OptimumRed \ 700f PermaTex# 81878.UltraCopper

* New Coolant

Parts & tools listed here are specificly for this Year+Make+Model ...; do not assume they fit your vehicle;
first verify your vehicle specs, closely inspect your engin & attached ThermoStat Housing, then confirm
chosen vendor part descriptions\recommendations are appropriate before purchasing\installing parts.
Time to replace other nearby parts: Hoses, Pump, RadiatorCap, Belt, Pulleys, Fan+Clutch, Tensioners..?

Old TStat Housing REMOVAL+INSPECTION+CLEANUP

New TStat Housing OPTIONS

Determined to not replace the old leaky part with a new leaky part, I found these options for improved housings. The aluminum ThermoStat Housing from SAS, pics & link below, appears the most rugid with Lower+Upper body machined as a single piece, minimizing potential for leaks; $130 ~ $160 depending on the accessories included. The SAS housing has EnginFlange guide tabs that can obstruct\break; bolts alone provide adequate alignment. The aluminum ThermoStat Housings from TAP \ SKP \ RAP \ GAP \ ZAB ..., pics & links below, appear alike as a group with Lower+Upper body joined by an ORing & 3Torx45Bushings, yet still an improvement vs the OEM part; $30 ~ $80 depending on accessories & vendor. SAS was too pricey for this "cheap bas'ard"; I chose the TAP kit with Valv +Sensors +Clips +ORings +Hose +Clamps +Bolts (less expensive SKP options became available later) then further improved this part with inverted TopBolts & RTV on the BodySeam +Sensor +EnginFlange ORings. After considering Threaded Sensors, I stayed with Clipped versions as room is limited under the IntakeManifold.

PICK ANY IMAGE ABOVE FOR A LARGER VIEW OR A VENDOR WEBLINK BELOW FOR MORE INFO.

* TAP# -254 +250

* SKP# SKRH144A \ SKRH144C

* RAP# CT83Y8 \ N654WN \ Q562KW

* GAP# 18628-02010725 \ 18628-02921819 \ 18628-07741273

* ZAB# ATK-8592-ACCS

* SAS# SA3 \ SA4 +SA5 +SA6 +SA7 +SA9

New TStat Housing ASSEMBLY+PREP+INSTALL

NOTE: Stant# 14748 ThermoStat LowerBypassDisc MUST BE GROUND NARROW slightly, to prevent jam open in the Housings throat & take advantage of 4RowAllAlumRadiators higher flow capacity.

New TStat Housing SENSOR CHANGE+MOVE

In 2020Jun, while changing the TimingChain Tensioner behind & left of this TStat housing, I removed the ClippedGray TempSensor on the TStat Housing, plugged that old hole, then drilled a new hole with a new ThreadedGray TempSensor as shown in the image below, improving clearance & access to the Tensioner.

Links To Related Info

Thanks go to the brave souls who've preceded me in similar adventures & freely shared their experience:

https://web.archive.org/web/20200809115410if_/https://www.explorerforum.com/forums/threads/possible-thermostat-problem-need-help.483910 Coolant TStat Replace

https://youtu.be/mAcwuhFOuuo?t=59 Coolant TStat Replace

https://youtu.be/Buyd-pMKQBk?t=78 Coolant TStat Replace

https://web.archive.org/web/20200514175645if_/https://www.solvay.us/en/binaries/Ryton-PPS-Mold-Temperature-205305.pdf Coolant Leak: PlasticPPS Parts

https://web.archive.org/web/20200809115849if_/https://www.explorerforum.com/forums/threads/sohc-v6-replace-rebuild-or-remanufactured.438266 Coolant Leak: TStatHousing Plastic

https://web.archive.org/web/20200301121249if_/http://howtoreplacefordthermostathousing.com/index.html Coolant Leak: TStatHousng Plastic Replace

https://youtu.be/fYp7_goQ2Qo?t=11 Coolant Leak: TStatHousing Plastic

https://youtu.be/z31LuE6KDdg?t=1 Coolant Leak: TStatHousing Plastic

https://youtu.be/4hna6iQHEw0?t=1 Coolant Leak: TStatHousing Plastic Replace

https://youtu.be/uUvlDJCreHc?t=1 Coolant Leak: TStatHousing Plastic Replace

https://youtu.be/CtogwA-ZJOw?t=1 Coolant Leak: TStatHousing Plastic Replace

https://youtu.be/lylAt1N_IBI?t=1 Coolant Leak: TStatHousing Plastic Replace

https://youtu.be/93aOMZ8om4g?t=15 Coolant Leak: TStatHousing Plastic Replace

https://youtu.be/6TcVOKXpyOI?t=2 Coolant Leak: TStatHousing Plastic Replace

https://youtu.be/wqkFLCbZ0R0?t=63 Coolant Leak: TStatHousing Plastic Replace

https://youtu.be/t57b-0ScZCw?t=1 Coolant Leak: TStatHousing Plastic Replac

https://youtu.be/bEJ-poFSPwA?t=1 Coolant Leak: TStatHousing Plastic Replace

https://youtu.be/sX5IhlnxGe0?t=1 Coolant Leak: TStatHousing Plastic Replace

https://youtu.be/sxGRjzB0tkQ?t=10 Coolant Leak: TStatHousing Plastic Replace

https://web.archive.org/web/20200323011029if_/http://www.naturecoastmustangs.com/articles/replacing_thermostat_housing_on_2005-2010_v6_mustang.aspx Coolant Leak: TStatHousing Alum Replace

https://www.sporttrac.org/search/7492435/?q=thermostat+leak&o=relevance Coolant Leak: TStatHousing Search

https://www.ranger-forums.com/search.php?do=showgcs&query=thermostat%20leak%204.0 Coolant Leak: TStatHousing Search

https://www.ford-trucks.com/forums/search.php?do=showgcs&query=4.0%20thermostat%20leak Coolant Leak: TStatHousing Search

https://www.reddit.com/search/?q=v6%204.0L%20thermostat%20housing Coolant Leak: TStatHousing Search

https://cse.google.com/cse?cx=partner-pub-1465533425503040:2946757341&q=thermostat%20housing&oq=thermostat%20housing&gs_l=partner-generic.3...5849.9517.0.10110.0.0.0.0.0.0.0.0..0.0.gsnos%2Cn%3D13...0.3679j902503j18...1.34.partner-generic..0.0.0 Coolant Leak: TStatHousing Search

https://youtu.be/eK8X7HAbzzg?t=39 SerpBelt+BeltTensioner Replace

https://youtu.be/H4jXC4MiDZA?t=47 SerpBelt+BeltIdler Replace

@@ Line 6: / Line 6: @@
 flange seam, notorious for leaking. My housing leaked into the "Cave" atop the engine under the Manifold,<br>
 creating a smelly Coolant+Grime swamp. Various Ford part#s for the housings have similar LowerBodies;<br>
-UpperBodies vary with 1 or 2 ThreadMt or ClipMt Sensors; TopCovers vary for RightHi\RightLo\ForeWard<br>
+UpperBodies vary with 1 or 2 ThreadMt or ClipMt Sensors; TopCovers vary with RightHi\RightLo\ForeWard<br>
-routed RadiatorHoses.  After concluding any like Plastic replacement part will tend to leak just as the factory part leaked, I upgraded to an Aluminum TStat housing in 2019Aug with no leak as of 2021Aug & another 10k+ miles.
+routed RadiatorHoses.  After concluding any new Plastic replacement will want to leak as the factory part<br>
+leaked, I upgraded to an Aluminum TStat Housing 2019Aug; no leaks as of 2022May & another 10k+ miles.<br>
-Minimal skill+patience, several hours, a level shop floor & the basic shop items below are needed for this repair:
+Minimal skill+patience, several hours, a level shop floor & the basic items below are needed for this repair:
 : * Hex+Torx SocketSet +DriverSet +Rachets +Adaptors +WrenchSet +SwivelExtensions
 : * ChannelLockPliers +NeedleNosePliers +ViceGripPliers
-: * WetVac +AirCompressor +ShopRags +PlasticGloves +DrainPan +DisposalContainers +AbsorbantLitter
+: * WetVac +AirCompressor +Rags +Gloves +DrainPan +DisposalContainers +AbsorbantLitter
+: * HiTemp RTVSealant [https://www.google.ca/search?q=permatex+optimum+red&tbm=isch&ved=2ahUKEwi72YzS4fX3AhXNAN8KHUj7DEcQ2-cCegQIABAA&oq=permatex+optimum+red&gs_lcp=CgNpbWcQAzIECAAQGDoFCAAQgAQ6BggAEB4QBToGCAAQHhAIUIcNWMt7YNmAAWgAcAB4AIABgwGIAZ8ZkgEFMTYuMTeYAQCgAQGqAQtnd3Mtd2l6LWltZ8ABAQ&sclient=img&ei=zZCLYvu-HM2B_AbI9rO4BA&bih=601&biw=1366 750f PermaTex# 27038.OptimumRed] \ [https://www.google.ca/search?q=permatex+ultra+copper+rtv&source=lnms&tbm=isch&sa=X&ved=2ahUKEwj2_t7P4fX3AhWPQjABHWbVDxoQ_AUoA3oECAIQBQ&biw=1366&bih=601 700f PermaTex# 81878.UltraCopper]
-: * RTV Sealant, 700f371c Permatex#UltraCopper Recommended
+: * [https://2001fordexplorersporttrac.fandom.com/Engine_Coolant New Coolant]
-: * New Coolant, 2Gallons 50%EG 50%H2O Recommended
+Parts & tools listed here are specificly for this Year+Make+Model ...; do not assume they fit your vehicle;<br>
-Parts & tools listed here are for this specific vehicle Year +Make +Model ...; do not assume they fit your vehicle; first verify your vehicle specs, closely inspect your engin & attached ThermoStat Housing, then confirm chosen vendor part descriptions\recommendations are appropriate before making purchase & working on your vehicle.  Time to replace any other nearby parts: Hoses, Pump, RadiatorCap, Belt, Pulleys, AC\FanClutch, Tensioners..?
+first verify your vehicle specs, closely inspect your engin & attached ThermoStat Housing, then confirm<br>
+chosen vendor part descriptions\recommendations are appropriate before purchasing\installing parts.<br>
+Time to replace other nearby parts: Hoses, Pump, RadiatorCap, Belt, Pulleys, Fan+Clutch, Tensioners..?<br>
 ==Old TStat Housing REMOVAL+INSPECTION+CLEANUP==
@@ Line 47: / Line 51: @@
 Image:2001.Ford.ExST Stat.Hous 0700 InStall.GIF|[https://static.wikia.nocookie.net/2001fordexplorersporttrac/images/f/f7/2001.Ford.ExST_Stat.Hous_0700_InStall.GIF NEW TSTAT HOUSING Install Step1]<br>* ORing+RTV On Housing EnginFlange<br>* Install Pump~TStat Red Hose+Clamps<br>* Snug 3 Bolts & Housing To Engin<br>* Install Valv+ORing+TopCover, No RTV<br>* Snug 3 Nuts On TopCover<br>* Allow 4Hr RTV SetUp<br><br>[https://static.wikia.nocookie.net/2001fordexplorersporttrac/images/f/f7/2001.Ford.ExST_Stat.Hous_0700_InStall.GIF NEW TSTAT HOUSING Install Step2]<br>* Torq 3 Bolts + 3 Nuts To 89InLb<br>* Connect Harness At TempSensors<br>* Trim RTV Flash<br>* Install Core~TStat "L" Hose+Clamps<br>* Install Radiator~TStat Hose+Clamps<br>* Connect Harness At Alternator<br>* Install IdlerPulley+Belt+Throttle+Duct<br>* Close Radiator Drain, Refill Coolant<br>* Connect Harness At BatteryNeg<br>* 15minEnginIdle With InteriorHeat On<br>* Leak+GaugeCheck, 1hrCoolOff<br><br>[https://static.wikia.nocookie.net/2001fordexplorersporttrac/images/f/f7/2001.Ford.ExST_Stat.Hous_0700_InStall.GIF NEW TSTAT HOUSING Install Step3]<br>* TopOff, Release Wheels+Brake<br>* 15minDriveTest With InteriorHeat On<br>* Leak+GaugeCheck, 1hrCoolOff<br><br>[https://static.wikia.nocookie.net/2001fordexplorersporttrac/images/f/f7/2001.Ford.ExST_Stat.Hous_0700_InStall.GIF NEW TSTAT HOUSING Install Step4]<br>* TopOff, Drive Normally<br>* Leak+Gauge+LevelCheck Routinely
 </gallery>
-[http://www.google.ca/search?q=%22183f+84c+thermostat%22+%22stant+14748%22&tbm=isch&ved=2ahUKEwiZo-fxvIruAhVHAs0KHcSzDeoQ2-cCegQIABAA&oq=%22183f+84c+thermostat%22+%22stant+14748%22&gs_lcp=CgNpbWcQA1CBFFjJbmDuc2gBcAB4AIAB1AGIAeEUkgEGMjQuNC4xmAEAoAEBqgELZ3dzLXdpei1pbWfAAQE&sclient=img&ei=JVb3X9n8DseEtAbE57bQDg&bih=612&biw=1366&hl=en-GB '''Warning: Stant# 14748 ThermoStat LowerBypassDisc MUST BE GROUND NARROW slightly, to prevent jam open in the Housing throat & to take advantage of 4RowAllAlumRadiators higher flow capacity.''']
+[http://www.google.ca/search?q=%22183f+84c+thermostat%22+%22stant+14748%22&tbm=isch&ved=2ahUKEwiZo-fxvIruAhVHAs0KHcSzDeoQ2-cCegQIABAA&oq=%22183f+84c+thermostat%22+%22stant+14748%22&gs_lcp=CgNpbWcQA1CBFFjJbmDuc2gBcAB4AIAB1AGIAeEUkgEGMjQuNC4xmAEAoAEBqgELZ3dzLXdpei1pbWfAAQE&sclient=img&ei=JVb3X9n8DseEtAbE57bQDg&bih=612&biw=1366&hl=en-GB '''NOTE: Stant# 14748 ThermoStat LowerBypassDisc MUST BE GROUND NARROW slightly, to prevent jam open in the Housings throat & take advantage of 4RowAllAlumRadiators higher flow capacity.''']
 :
 ==New TStat Housing SENSOR CHANGE+MOVE==
-[http://2001fordexplorersporttrac.fandom.com/Engine_Oil_Pressurized_TimingTensioners In 2020Jun, while changing the TimingChain Tensioner located behind & left of this TStat housing, I removed the ClippedGray TempSensor on the TStat Housing, plugged that hole, drilled a new hole with a new ThreadedGray TempSensor as shown in the image below, that allows improved working clearance & access to the Tensioner.]
+[http://2001fordexplorersporttrac.fandom.com/Engine_Oil_Pressurized_TimingTensioners In 2020Jun, while changing the TimingChain Tensioner behind & left of this TStat housing, I removed the ClippedGray TempSensor on the TStat Housing, plugged that old hole, then drilled a new hole with a new ThreadedGray TempSensor as shown in the image below, improving clearance & access to the Tensioner.]
 <gallery hideaddbutton=true position=left spacing=small bordersize=none captionposition=below captionalign=left widths=215 >
 Image:2001.Ford.ExST Engi.Cool Stat.Hous 0750 Changed.GIF|[https://static.wikia.nocookie.net/2001fordexplorersporttrac/images/9/9a/2001.Ford.ExST_Engi.Cool_Stat.Hous_0750_Changed.GIF NEW TSTAT HOUSING Sensor Move]<br>* ClippedGray~Control Sensor Removed<br>* ThreadedGray~Control Sensor Added<br>* Improves Access To TimingTensioner
 </gallery>
 :
-==Old TStat Housing REBUILT==
-A few months after installing the new Aluminum TStat Housing, while doing some garage cleaning I came across the old Plastic TStat Housing; almost to the trash can, a question came to mind: might the Plastic BodySeam be taken apart & a root cause of the notorious leaks determined?  After some 2hrs of gentle work with a razor knife, keyhole saw, brass brush, grinder..., the Lower+Upper body pieces were separated & cleaned, revealing a very weak GlueJoint\HeatSeal.  Furthering this whim, pictured below is my ReBuild of the Plastic Housing as a backup.    While I would trust this ReBuild more than a new Plastic Housing, an Aluminum Housing remains the preference.
-<gallery hideaddbutton=true position=left spacing=small bordersize=none captionposition=below captionalign=left widths=215 >
-Image:2001.Ford.ExST Stat.Hous 0800 ReBuild.GIF|[https://static.wikia.nocookie.net/2001fordexplorersporttrac/images/4/43/2001.Ford.ExST_Stat.Hous_0800_ReBuild.GIF OLD TSTAT HOUSING ReBuilt Lower]<br>* EnginBolt MetalSleeves Ground Short<br>* EnginFlange Tabs Not Reqd, Removed<br>* TopBoltsInverted +JamNuts +LockNuts
-Image:2001.Ford.ExST Stat.Hous 0810 ReBuild.GIF|[https://static.wikia.nocookie.net/2001fordexplorersporttrac/images/4/4d/2001.Ford.ExST_Stat.Hous_0810_ReBuild.GIF OLD TSTAT HOUSING ReBuilt Upper]<br>* TopBolt MetalSleeves Ground Short<br>* RTV DoubleCoat On Lower+Upper
-Image:2001.Ford.ExST Stat.Hous 0820 ReBuild.GIF|[https://static.wikia.nocookie.net/2001fordexplorersporttrac/images/f/fd/2001.Ford.ExST_Stat.Hous_0820_ReBuild.GIF OLD TSTAT HOUSING ReAssembly]<br>* EnginBolt TemporaryClampNuts<br>* TopBolt TemporaryClampNuts<br>* RTV LiteCoat On TempSensor ORings
-</gallery>
 ==Links To Related Info==
 Thanks go to the brave souls who've preceded me in similar adventures & freely shared their experience:<br>