4.0 leak in thermostat housing again! smh...

[MidnightRider]

Yep,
Defintely recommend swapping the JunkPlastic TStatHousing to an Aluminum Housing.
Basicly 2 versions of Aluminum Housing available: one from SimmonsAutoSportz & all the others.
Either Aluminum version has slight advantage\disadvantage to the other;
either Aluminum version is much better than the JunkPlastic FactoryOE\AfterMarket versions sold at your local parts store.
Click here for more on Aluminum TStatHousings for the V6~4.0L~SOHC.
Click here for more on OilPressurized TimingTensioners for the V6~4.0L~SOHC.

Thanks for posting, I really appreciate the tensioner tips!

 

[Burnsy]

Agreed, especially on something like this. Gone are the days when a thermostat change out was a two bolt 1 beer job. smh...

Damn im kinda glad i have a 3.0, my thermostat change out IS 2 bolts and a beer lol

 

[rubydist]

I put the cast aluminum thermostat housing on my 09 nearly a year ago and its working just like it should. I don't recall which brand I got, but one of the rockauto options. The only issue I had was that one of the hose clamps was bad, so even though it felt tight, it was not and it leaked. As soon as I put a good clamp on there, all is well.

 

[sgtsandman]

Stick with Motorcraft for the chain tensioners. Don't use aftermarket. When you order the tensioners, be sure to get the gaskets (washers), which are separate part numbers. Left and right tensioners are different, but take the same gasket. Check other threads here for the part numbers and tips for installation.

Glad you found the Simmons housing. They ain't cheap, but they're good.

Motorcraft is a good bet for sure. Cloyes is also a good option and they come with the gasket/washer. So, Cloyes is a good alternate if you can’t get the Motorcraft one.

 

[Roert42]

I've used Cloyes in both my sohc motors without issues. I wouldn't have any issue using them again.



I would recommend pulling the intake, I think it's 8 bolts pull the intake off, and you have complete access to the whole top. So much easier. I've pulled the intake on my 03 a few times, it only takes two minutes and makes everything else so much easier to get at. I think you need a T27 or T30 for the intake bolts, 1/4 socket, some extensions and a ratchet.

The intake gaskets, one for each runner, are silicone, so you can reuse them as long as they're not cracked to torn. Just wipe the goop off and slap it back together.

 

[DILLARD000]

In last 3~4years, installed several pairs of Ford Tensioners, one pair of Cloyes Tensioners (friends vehicle+choice due to availability+price);
external build quality of both brands is good, both brands have worked without complant since;
washer\seal\gasket on the Ford Tensioners is more loose & thus more difficult to get seated correctly without leaking,
Cloyes washer is slightly thicker not so loose & easier to install.