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Cooling system bypass outlet leak - unavailable part needed

TheOldBear

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My 2003 ranger has a leak in a cooling system water outlet - it's the part where a bypass hose comes out of the thermostat housing, and has a fitting to attach a temperature sender.

After spending quite some time on the phone with the folks at parts.ford.com it was determined that this is an obsolete part XL5Z-8592-AB , no longer in the Ford inventory - and also not available from vintage parts or green sales two of Ford's recommended vendors for 'new old stock' parts.

I'm going to attempt to remove the part and and see what sort of metal it is made from - its possible that the hole could be patched [solder, braze, tig-weld...] or plugged [jb-weld?] depending on what the part was made from. [And if I can find a shop with suitable skills and tools].
 


gw33gp

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It also states it is for a 2.3 or 2.5 L engine. Is the thermostat housing the same for a 3.0?
 

franklin2

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It also states it is for a 2.3 or 2.5 L engine. Is the thermostat housing the same for a 3.0?
I used the part number he gave in his post above. Maybe that is part of his problem, he has the wrong part number?
 

tinman_72

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I used the part number he gave in his post above. Maybe that is part of his problem, he has the wrong part number?
Check again, the part numbers are not the same. ;)
 

ekrampitzjr

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The original Ford part might not be available, but check the aftermarket. Either Dorman 902-1041 or Four Seasons 85024 is supposed to be a replacement. Several of each are available on eBay.

Yeah, yeah, I know, Dorman. But any port in a storm, right? Given the nature of the part, I doubt repair of the old part would be worthwhile.
 

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