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The thermostat water outlet failure is a very common failure in the Ford Explorer 2002. It is recommended that you replace the water outlet, the sensor, the thermostat and both seals one beneath the housing and engine and one between the thermostat cover and the housing itself. First disconnect the sensor cable, remove the three hoses, remove the three bolts that connects the housing to the engine and pull the part out. Clean the seat on the engine top, install the seals and reinstall the new part. Connect the hoses and the sensor cable. Refill Engine Coolant, Turn engine, wait for normal operating temperature and check for leaks. Parts from $200 to $250. Total labor 1 hour.

The base under the thermostat is a two piece molded plastic bonded together.

When the bond fails coolant leaks at the seam. A couple of screwdrivers an a little care they are not hard to separate without damage. There are three captive nuts that attach the thermostat cover but they do nothing to hold the base together (this is the main reason it fails). Discard the nuts, use three longer bolts that will hold all three pieces together. Bond the seam with black RTV. You can bolt the thermostat cover on first (with thermostat inside) and then bolt the assembly to its mount. One hour or less and no cost except a little RTV. OldAxe 80 and retired.

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Q: What the thermostat housing water outlet on a 2002 explorer 4.0 is bolted to There is a leak below where it bolts to not the housing seal itself but the next seal down?
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