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There are a few reasons for a leak coming from and around the thermostat on most Focus cars:

  • The inner (thin plastic) wall inside the thermostat housing may have cracked - you will need to replace the thermostat housing - check http://www.focushacks.com/index.php?modid=59&ht=Replacing%20the%20thermostat%20and/or%20thermostat%20housing for detailed instructions
  • The O-ring may have disintegrated. You need #203 O-Ring replacement. This is an engineering mistake on a lot of Foci, as they use Nitrile O-rings which don't resist high temperatures well, if you are replacing them use Viton.
  • The thermostat housing gasket may have cracked. Even if it's not and you end up changing the thermostat housing, you should probably change it (cheap and avoids further problems)
Further reading:
http://forums.focaljet.com/svt-headquarters/466771-coolant-leaks-cheap-fix-info.html
http://www.carcomplaints.com/Ford/Focus/2002/cooling_system/leaking_thermostat_housing.shtml
http://forums.focaljet.com/problems-service-recalls/508657-slow-coolant-leak.html
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Q: We have noticed a small leak coming from the thermostat on our ford focus it only seems to be there when the engine is cold what should we do?
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