THERMOSTAT HOUSING REPLACEMENT ON FORD 4.0 SOHC

For education only - do not attempt. This is the process for a 2002 Ford Ranger. The process may be similar for an explorer with the same engine.

[@paulanderson388]

I just replaced the thermostat housing on my 2006 Ford Ranger and the job was much easier after watching this video. The steps on what to remove and the order of the removal and installation of the sensors was extremely informative and saved the mistakes of trial and error. Unless the sensors are defective you can obtain replacement o-rings at any automotive supply store or Ace hardware. The o-rings will need to be replaced if you are going to reuse the sensors as the old o-rings have "taken a set" and you will be guaranteed a leak. Thank You so much for this video. It was extremely helpful.

[@motoforlyfe]

Thanks Paul, glad it was helpful!

[@angelgjr1999]

motoforlyfe What size to get out the bottom part of the thermostat housing? The one u have your index finger at 4:42?? Please help. And what way do you turn to take it off?

[@cesarorozco2638]

So same sensors just new o rings ?

[@richardkey4289]

I just replaced my cracked thermo .housing on a 4.0L Ranger, 2 things that caused a delay: * The sensor wiring plug ( mine is a single sensor) has to be clicked into place before setting housing onto its location . * The farthest rearward bolt, of the three that attach the housing to the engine block, needs to be dropped into its place on the housing before housing is set into its location . There was no room to do these two things after placing the housing into its spot . I used a 1/4" swivel fitting on an extension ( like a tiny u joint connection) to spin the three housing anchor bolts down . I used a green kitchen scrub pad to clean the engine block surface where the housing mates to it . No leaks, all is well, now it's time for the tough job - burst heater core replacement . Ouch . All this because I had weak % coolant , & a cold spell appeared . Check your coolant ! An hour of work to check/ top up/ replace coolant is better than a burst housing/ rad/ hoses/ heater core

[@BB-hi5of]

I took my intake off to do this. Took about 40 mins extra to pull the intake manifold off however it just made the job super easy. I had a broken bolt and one that stripped in the rear, however once i got the extra clearance it was super easy to tackle.

[@tonethetiger777]

Good info- I too have a stuck bolt on the housing…I gave it some JB weld and an old socket and going to try and remove tomorrow. I may have to go the intake removal route if the JB doesn’t work. Any tips on the removal of the intake?

[@jman6214]

I wish somebody would show how they put the housing unit in. I've watched several of these videos and no one shows how they did it. They just skip to the end. That's of no help.

[@chasematthew6904]

Bc he is a dumbass. That the only reason we are watching

[@MacMcCabe2456]

Good video, thank you. It so perplexing why the manufacturers o what they do and the engineers. Used to be you could change a thermostat in 20 minutes tops back in the day. For folks not mechanically inclined, I can only imagine what a shop would charge to do this repair.

[@MalcOfLincoln]

Good job young man :) It's called the joys of motoring lol. When cars were much simpler, the thermostat was dead easy to access. Trouble was that an ally housing was mounted on a cast steel water pump. Bolts corroded in, and 9 times out of 10 snapped. Guess it's how we learned to remove broken bolts lol.

[@motoforlyfe]

Sounds like that job was just as difficult despite easier access!

[@MalcOfLincoln]

Yeah! sometimes 5 minutes, sometimes 5 hours lol. Don't you just love working on cars :)

[@not2fast4u2c]

Man they sure have made it hard to work on newer vehicles !!! You did a good job on it .I like the fishing line idea

[@motoforlyfe]

Thanks buddy!

[@victortamayo5108]

Saved me so much labor time appreciate you !

[@aaadeejay]

Wow, I wouldn't have attempted to do this by myself if it wasn't for your video. I have a 2002 Sport Trac and although I had to remove a few more things to get access to the thermostat housing and I was able to do it under a few hours. That thermostat housing is so tightly crammed into such limited space it was like puzzle getting it back in there. Thank you very much, I probably saved hundred of $$$.

[@motoforlyfe]

Yeah they don't make it easy to get to, that's for sure!

[@regsparkes6507]

I don't have a 4.0 litre Ford engine to work on, but I watched with a lot of interest, just in case a buddy ( who does have this engine in his Ranger) runs into trouble, then I figure I'm armed with this knowledge you taught me today. Thanks dirtbike !

[@motoforlyfe]

Good luck Reg!

[@georgehenry6432]

I just replaceed the lower houseing on my 2005 4x4 ranger useing this video.Would not have been able to do it without it.I was just reading another post from a guy thats probably close to my age and you could just about change a thermostat in the time it took to fill your gas tank! Why do I have 2 seasors that are both exactly the same (outside anyway) both grey. GREAT VIDEO) Thanks, George

[@NickyMaui]

Thanks a bunch DB5100. Your help is incredible. I had good luck with the dorman unit. PS I have a sweet Antron 99 on my house 2 miles outside Philly if you take it down I will give you my Cobra 2000 GTL Base station. I can also hook you up with a 50 foot tower located in Cape May.

[@bobjayp]

Must be a reason everyone's vid for this job skips actually removing/installing the sensors and bolts. All they show is the before and after. They leave out the swearing and wiggling and various attempts to get a wrench on old hidden bolts.

[@coolrides]

Nicely done! I like your caveat at the end..."do not attempt unless you know what you are doing!" Another key ingredient...patience! :) Jack

[@motoforlyfe]

Thanks for watching Jack!

[@leehathorn2845]

You skipped the most important part, i.e., how to replace the thermostat housing itself.

[@DesertJeff]

ROFL I saw that too.

[@robertlesliebobo4760]

its because how much of a bitch it is to do

[@jman6214]

@@robertlesliebobo4760 Even more of a reason to show it.

[@mallorycainjr.1921]

Anyone found a way to replace the housing? Does someone have a video on it

[@Lol-ub8yh]

@@mallorycainjr.1921it literally has 3 bolts Lol

[@loveofit6498]

Excellent tips, thank you so much for going to the trouble of making and posting this!!!

[@motoforlyfe]

+loveofit Thanks for leaving such a nice comment! Glad I could help

[@jamesgoforth1606]

Great job on the video. Five out of five stars.

[@joshuastoller1772]

Thanks for the video man. This is my project this afternoon. Wish me luck!

[@johnbrownlee7623]

What I just did, Take the air box OUT, remove the alternator, and bracket.....Yes it was faster, and made for a safer job.............Thanks.............John.

[@sigguy1361]

Very helpful, thanks. I'll give it a go. I'm all about doing my own stuff if I can - saves moolah. I've had the same problem for years where the temp gauge won't work and I think it's the therm sensor. Everything I've read says it's the therm sensor.

[@motoforlyfe]

Thanks, hope you can fix your problem.

[@sigguy1361]

dirtbike5100 Replaced the thermostat and the two sensors (just for good measure) and then got a new error - EGR sensor was bad. Replaced that, and all is great. No CEL, no shifting issues, nada. Sweet. Off to emissions

[@Dontez82]

Thank you so much for this video! This is the same setup as my 2001 Explorer Sport! Much appreciated.

[@motoforlyfe]

Calvin McHoward Thanks for the comment! I'm glad you found the video helpful!

[@fred306801]

How do you tell which sensor goes in which hole ? Both of mine are gray on top, where they connect. The wire's leading up to the sensors one has as gray cap and the other red. Never mind just got back from Ford they took a look at the Parts i got from NAPA. NAPA had sold me two new sensors both with the gray caps. I get them installed and go to put the wire clips in. It was hitting a brick wall. The clips on the tips are pointed out wards. They were trying to bore a hole through the thermostat housing. I tried everything I could think of but once the clips hit those spots they bore, they would Not go in. So I used a paper clip. So far No leaks and it is holding. I bent the paper clip into a horse shoe shape. Then coated both of the sensors with vaseline, petroleum jell, slid them into into the thermostat housing. Took each end of the paper clip and placed into the slot and pushed it threw, so it would wrap around the sensor and out the other side then curled the ends.

[@mikefreeman4430]

my truck saved me time by draining its own coolant

[@BarbaraWynn]

replaced 03 ranger 4.0 .used the metal one .every piece of the housing body was leaking . started leaking at 70,000 miles . This part is a joke plastic really Ford . My son and i replaced it yesterday . Job is hard even with two people . looks like Ford made it easy for 05 -10 models . This part should have been a Ford recall . Seems to me they should have learned of the plastic problems back with the 96, 97 98 4.6 motors they had to recall on the intake manifold that was plastic and would leak or at worst explode open spewing out all the water at once . That recall manifold was in the front of the intake manifold they made the water passage port out of plastic the replace part was metal . So why did they do this again to the consumer ?

[@billz1316]

Recalls are for safety defects.....not shitty parts. It's a problem sure, but OEMs don't issue recalls without a significant safety risks

[@mportklr]

8:29....Follow this tip!!!! I didn't and it took me 2 days to find the retaining clip. Autozone and Oreilley's doesn't sell them. A salvage yard didn't want to sell them to me unless I bought the whole housing unit for 100.00. I finally found it and I tied a piece of sewing string just in case it flies off again.

[@angelgjr1999]

mportklr What size to get out the bottom part of the thermostat housing? The one u have his index finger at 4:42?? Please help. And what way do you turn to take it off?

[@kenprouty1366]

I didn't use clip tip when changing the sensor and had to buy the clip that you tie the fishing line to for 9.98 at the dealer.

[@motoforlyfe]

+Ken Prouty 10 bucks for a little clip! That's rough!

[@jasonmushersee]

That rain was really fighting you. Would drive me crazy. Remember to bleed the cooling system.

[@ziggassedup]

Love the fishing line idea.

[@motoforlyfe]

Thanks for watching mate!

[@dywildatheart]

Thank you so much for the video, very informative.

[@motoforlyfe]

Glad you found it helpful Dave!

[@billz1316]

Just a tip from experience: when this housing starts to leak again, buy the Dorman aftermarket part or an equivalent. The Ford parts are trash and will just leak again.

[@motoforlyfe]

Thanks for the tip!

[@MC-hs4mf]

motoforlyfe is rtv needed?

[@billz1316]

C. M. No rtv here.....o rings only

[@MC-hs4mf]

Bill Z finished job, now I KNOW.

[@angelgjr1999]

What size to get out the bottom part of the thermostat housing? The one u have your index finger at 4:42?? Please help. And what way do you turn to take it off?

[@outdoorsman310]

If I remember right, you don't need to pull the throttle body if you have a swivel socket

[@willt9172]

Nice job! Love the truck!

[@motoforlyfe]

Thanks Will!

[@TONE3846]

I have a 2003 ford ranger 4.0 and I have a leak somewhere its not the water pump but I do see green around the thermostat housing it's more on the right side not the left

[@motoforlyfe]

Could be the thermostat housing! I'd check it along with the temperature sensors.

[@krazy45cat]

Nice job !!! You guys did a great job with Roadkings car ass well , Gerry

[@motoforlyfe]

Thanks Gerry!

[@blacbean03]

YOU SKIPPED ALL the Important part of WHAT DID YOU USE OR HOW DID YOU get housing back in

[@Lol-ub8yh]

if you don’t know how to this thermostat housing fix you should not be working on your car lol

[@C0Y0TE5]

@@Lol-ub8yh WRONG. The purpose of the video is SHOW how to do it. IT is a difficult job, and a newbie-killer. A good deal of wrenching experience is necessary.

[@patrickharrington3436]

Good video and tips!

[@MikeSosnowski94]

Thanks for the video, it helped a ton!

[@motoforlyfe]

+Mike Sosnowski No problem Mike! Glad we could be of assistance!

[@johnnyrouse2713]

Only problem some of the sensors don't slide in some of them screw in

[@danielcarnemolla8125]

it came off and goes in but won't go all the way back in its all tight but not fully tightin just needs to go in just a lil bit more

[@CHOOPISWOOPIS]

used this to help my friend fix his 2004 ford explorer

[@motoforlyfe]

+CHOOPIS WOOPIS Nice! Hope it was helpful

[@mcdatacomm155]

So no paper, rubber, or cork gasket between upper or lower, just the rubber gasket that fits into that round slot? No glue or gasket sealer required?

[@teiaperigosa]

where did the little tabs break off? did they they fall into the engine? two of my tabs broke but I could only find one... not sure how seriously I need to look for it...

[@klc317]

Nice explanation. Im going to put new timing chain tensioners (OEM Ford of course) in my '03 Ranger soon. It only has 69k miles but over the past few years has had that timing chain rattle for a second on some cold start ups and no other times so I'm pretty sure the tensioners are just worn out. I wonder if I should just go ahead and order a new thermostat housing and gasket while I'm at Ford getting the tensioners just in case I break those tabs while taking it loose to get the top tensioner out just in case!....probably not a bad idea! The truck isn't a daily driver but I always get annoyed when something like that breaks and I cant finish the job the same day. And yea, I agree with you on things such as this you're much better off just spending the extra little bit to get the OEM parts.

[@motoforlyfe]

You might as well. The tabs can get pretty brittle after a while.

[@dougbauer8608]

My sensors are bad and i wanted to know the exact name of them, i was able to find one but the other one is diffrent and no one seems to know Thanks!

[@harrythelocksmith]

Check part numbers I think they're both the same,

[@eloyjgrado8267]

Great job dude

[@slushjoe]

Thank you

[@trumpetvids]

You skipped the main thing I was looking for - getting that rear bolt out - **bang head**

[@motoforlyfe]

Use a long extension with a universal on the end. That's how I did it.

[@BlueOvals24]

Maybe you can help me out here since you seem to know some about the 4.0L SOHC cooling system. My 01 makes a loud noise from the fan, almost like a leaf blower. It got really loud when the engine was running past 4000 rpm, so after doing some research, I figured it might be the fan clutch. I took it to a local NAPA shop and they said the fan clutch was fine but my AC compressor needed to be replaced. I let them replace it and now the noise doesn't get as bad. But it still happens while the engine is warming up and after a good 20 mins or so of city driving every now and then when I accelerate from a stop. It also might help to mention that I live in Arizona where it gets really hot in the summer. Also, before I bought it, the radiator had been replaced along with some hoses and an oil/tranny cooler. I would really appreciate if you could give some advice on how to fix this please.

[@motoforlyfe]

It certainly sounds like the fan clutch to me. Maybe you could make a video so we can hear exactly what it sounds like.

[@BlueOvals24]

Go on my channel, i recently made an exhaust video after i got a new muffler. The 1st half of it is with the stock system and at first you'll be able to hear it, then it goes away

[@dilanhernandez612]

Could you provide a link to these part please

[@ponch2100]

What year us the ranger your repairing?

[@jonathanaldridge8187]

You don't show or describe any of the difficult parts.

[@angelgjr1999]

What size to get out the bottom part of the thermostat housing? The one u have your index finger at 4:42?? Please help. And what way do you turn to take it off?

[@motoforlyfe]

I did this three years ago so I don't remember, but if I had to guess I would say 8 or 10mm. Turn counterclockwise to remove the bolts.

[@tectalabyss]

I hate those plastic part's. They are made to fail. It's a deal between the oil company's and the car manufactures. IMHO at least.

[@motoforlyfe]

In my opinion it's because plastic parts are cheaper to make...but you never know!

[@77portraits]

Plastic is made from oil, he was correct

[@RunAround7510]

plastic is also lighter....miles per gallon baby!

[@chrislmcnair]

I have a question, while trying to get the back bold out to get the thermostat housing out I crack a hose, it is a plastic hose that has rubber around it and it goes to a T connector that two other hoses are connected to that run along the manifold, do you have any ides what that hose is called? I really appreciate you making this video!

[@ramoncastillo8122]

How did you get that back bolt out? Having trouble getting it out. Thanks in advance.

[@chrislmcnair]

@@ramoncastillo8122 I think I used two small extensions with a wobble socket it in middle. You'll have to use a smaller ratchet with a longer extension hooked to the ratched then wobble socket then small extension lol. It was fun but, it worked. Good luck!

[@ramoncastillo8122]

c m thanks for the info man, I was able to use a small ratchet with a 6 in extension/u joint and got it from the side. Terrible design, such an easy job made hard due to no room lol

[@chrislmcnair]

@@ramoncastillo8122 yeah it really sucks lol and to make it worse I ended up doing the upper and lower manifold gaskets a month later so I had to take the manifold off anyway! Glad you were able to get it done!

[@BRADustin]

Had my entire housing, thermostat and sensors changed on my 01 4.0 and from the very first grade I drove the needle pegged hot. Never blew coolant or steam out the tailpipe. Level ground is fine. Could the sensor wires be swapped to make it peg hot? Any suggestions?

[@motoforlyfe]

Does it peg as soon as you turn the ignition on?

[@BRADustin]

+dirtbike5100 No, it runs hotter than originally but, depending on the weather it'll climb while climbing in elevation.

[@terrycarroll656]

How tite r the bolts for the housing

[@franciscoz6010]

Where is the pcv valve?

[@shawnmrfixitlee6478]

It always rains when you want to record a video man .. Every time !!

[@motoforlyfe]

Every dang time!!

[@MC-hs4mf]

Mine started leaking and overhearing and of course it was pouring rain and lightning.

[@foxywolf2009]

ty going totry this tomorrow :)

[@motoforlyfe]

+paTricia Klasinz Hope it went well!

[@foxywolf2009]

+dirtbike5100 it was so easy to do thank you so much

[@matthewrice1226]

Not expecting an answer but was the bottom of the housing leaking? Mine i think is doing same out of the bottom portion of the housing.

[@motoforlyfe]

Yes, bottom was leaking. That was what prompted me to replace it. Hope this helps!

[@matthewrice1226]

Yup did mine today. And it stopped so I’m happy. Had to use liquid gasket stuff because the bottom was pitted in 5-6 different parts. But it’s done and it works beautiful.

[@ryleegi1972]

My ranger’s temp gauge goes to hot at the same time the heater will start to blow cool air. Heater starts to blow warm air and temp drops. Any idea?

[@C0Y0TE5]

Low coolant level.

[@Lugenfabrik]

I was thinking about trying this myself, but after watching this video...nope.

[@MikeVODKA]

i just made this same repair on my 01 explorer. now engine starts but dies in 2 seconds wont idol and smells rich. any ideas what might be the trouble?

[@motoforlyfe]

Check to see if you forgot to plug in any sensors. Sounds like your mass air flow sensor might not be hooked up.

[@williamdaniels6943]

if it starts and dies it is most likely in the elec resistance system.

[@stansmad]

@@williamdaniels6943 - IAC VALVE , at least that's what solved my problems with the exact same issues as above .

[@dannyfisher9578]

can some one show me a video of 2000 mercury marquis video to change housing unit on thermostat

[@jrunberg]

shylocks at Firestone charged me $200 for that lower housing

[@DriveShaftDrew]

good vid

[@motoforlyfe]

Thanks Drew

[@MC-hs4mf]

If outlet is leaking do you have to replace sensors? Is rtv needed? U mentioned the hose that goes to water pump but didn't see u disconnect or connect it.

[@JesusGodHolySpirit3]

How much did you pay for this genuine ford "thermostat housing" part? Was it from Motorcraft you purchased it?

[@markojovanovski3550]

does it matter how you position the thermostat or it doesnt matter as long as it sits good?

[@motoforlyfe]

+Marko Jovanovski As long as the thermostat is sitting right side up and the gasket is properly seated, you should not have any problems

[@jamesbrogan5247]

Does the three ears on the bottom of the housing must be there? 2 of me me are broke off.

[@motoforlyfe]

Two of mine broke off and I found that it eventually started to leak coolant. I'm unsure if they MUST be there or not.

[@audiarcher2714]

Torque specs? Anyone 🙏

[@phillipgarcia4518]

thank you . very helpful. funny too. lol

[@motoforlyfe]

+Phillip Garcia Haha thanks!

[@lorettamccall0927]

? The therstate do u put the gasket under or on top of the therstate

[@pauldelsignor2970]

Loretta MCcall you put in on top

[@UnitCrane514]

Your missing your oil fill cap bud!!! Hey have you seen the airbox mod on the Ranger Station? I did it to my truck, took 15 minutes and I gained 2 mpg combined with my Magnaflow exhaust on my Ranger. Worth a try!

[@motoforlyfe]

Do you mean removing the air intake silencer? It didn't do any good for me, actually might have made my mileage worse

[@UnitCrane514]

Yessir! The funnel that goes in the front of the airbox. Worked wonders on my rig! 😊 depends on your driving, I drive a lot of highway miles!

[@hakeemhenderson6119]

will this process work for a 1986 Chevy camaro?

[@motoforlyfe]

I highly doubt it.

[@danielcarnemolla8125]

why won't my bolt go all the way back in on my thermostat on a v8 99 Mercury Mountaineer

[@motoforlyfe]

Daniel Carnemolla Make sure you don't have it cross-threaded. Also check to see if all three bolts are the same length. One might be longer.

[@danielcarnemolla8125]

dirtbike5100 it goes in no problem but not all the way but almost

[@motoforlyfe]

Daniel Carnemolla Are you sure that all three bolts are the same length?

[@danielcarnemolla8125]

There is only 2 I looked and made sure to look

[@motoforlyfe]

Maybe there is a spacer missing or something has fallen in the hole preventing the bolt from going in all the way

[@RunAround7510]

what is the hose called that is pointed to at 8:54?

[@MC-hs4mf]

Bypass maybe

[@buddylight2191]

Way too much junk built in that truck.

[@angelgjr1999]

BUDDY LIGHT I agree, its impossible to mod these trucks.

[@cstoltz8236]

I didn't know the 4.0s took the dexcoolant or the orange coolant. Does it matter which coolant you use use because I'm using the green coolant

[@jman6214]

You're supposed to use the green coolant

[@skipmalaney9233]

Extended life coolant ford does not use DeX cool gm product

[@kabal28]

And that's why I payed $340 in labor for someone else to do it lol

[@jamesfelty279]

Went through 3 of these. Plastic. Come on Ford. Should be a recall on that junk.

[@C0Y0TE5]

Need specific torque. And careful NOT to break the tabs on the bottom. And don't buy aftermarket cheap Chinese made parts. -- But U R right: the ford 4.0 is a mess of bad designs.

[@jamesbryansoto4318]

Clips wouldn't go in, spent hours trying to put them in. What the shit?! Simple things sometimes become boss fights. Had to hack it, improvised with paper clips. Also one of the the main bolts snapped, took another hour trying to get that out. So I'm pretty much done, just need to buy new bolts.

[@angelgjr1999]

James S What size to get out the bottom part of the thermostat housing? The one u have his index finger at 4:42?? Please help. And what way do you turn to take it off?

[@angelmaxwell1393]

Can u come do mine lol

[@MC-hs4mf]

Angel Maxwell lol

[@johnmerrill332]

should have bought an aluminum one, dont replace it with crappy stock one lol

[@TacoTodd_420]

That was the most pointless video

[@prabcare]

HI5, amazing video buddy! #prathameshbhat7288

[@crashmavrick1076]

Thank you.

[@josearanda3930]

Thank you.