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1997 Explorer thermostat housing replacement

Discussion in 'Stock 1995 - 2001 Explorers' started by bar422, September 28, 2011.

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    1. bar422

      bar422 New Member

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      I have a 97 Explorer 6-cyl. with SOHC and I need to do the thermostat housing. It looks like it would be alot easier if you take the intake off. Does anyone have any pics showing how to do this? I don't want to just start pulling bolts/screws. Any help would be appreciated.--Thanks!
       
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    3. ophidia

      ophidia Member

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      I don't have any pics, but I've had the upper intake off of mine a number of times and it's pretty easy. There are 8 t-30 torx bolts holding it on. Rough instructions:

      Remove the splash shield from the intake (4 small bolts-- 11/32 I think)
      Remove the air intake hose from between the throttle body and air box (2 hose clamps)
      Disconnect the cables from the throttle body (should be self explanatory when you look at them)
      Remove the two bolts that hold the cables to the intake. I think those are 11/32 too.
      Disconnect the electrical connector from the throttle body and remove the throttle body (4 8mm bolts)
      Disconnect the brake booster line from the brake booster. Then, remove the two vacuum lines that attach on the back of the manifold, one on each side, pointing towards the firewall. Then, pull out the quick disconnects and pop off the hoses connecting to the bottom of the intake on each side.
      Disconnect the electrical connector from the IAC.
      Remove the 8 t30 torx bolts and maneuver the intake off. The EGR pipe that goes into it by the throttle body is stubborn, but will come out if you keep working at it. It's in there pretty snug.

      That should be about it. Check it over closely to make sure you didn't miss any lines that I forgot about when posting this. I'm doing it from memory.

      There is a pattern to torque the bolts back down when putting it back on-- it's in the Haynes manual-- otherwise someone here might have the diagram to post.

      Hope this helps.
       
    4. bar422

      bar422 New Member

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      Thanks for the reply! I was thinking about getting a Haynes manual for it anyway so now might be a good time. Anymore info or pictures would be appreciated.--Thanks!
       
    5. swshawaii

      swshawaii Explorer Addict

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    6. bar422

      bar422 New Member

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      That one is different than mine....possibly newer? Any more help with this would be great!
       
    7. J_C

      J_C Active Member

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      Pulling bolts is pretty much what you do, though if one is hard to get to, sometimes it's easier to go ahead and remove a part partially blocking it instead of fighting against that part the whole time.
       
    8. crazymind

      crazymind Active Member

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      Since you will have it off I would put on the 03 sport track housing o, I have it on my 99. Its a little better for the fact the it has pop in sensors vs the ones the screw in. It'll be a little more expensive as you have to get new sensors as well but you wont have to worry bout them stripping the housing out. I had to replace a sensor and the brass nut stripped the housing
       
    9. swshawaii

      swshawaii Explorer Addict

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    10. bar422

      bar422 New Member

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      What sensors are in the housing? I know there are a couple but not sure which ones. Might as well change them too......Thanks for all the replies so far and any more input is greatly appreciated.
       
    11. crazymind

      crazymind Active Member

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      They are both engine coolant sensors one is for the Edmund and one is for the gaugegauge
       
    12. swshawaii

      swshawaii Explorer Addict

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      The OEM replacement lower housing is updated, no longer uses threaded sensors.
      You will have to replace the sensors with the new o-ring type with the new housing.
      To confirm Motorcraft part numbers, use your VIN below. Check Amazon for pricing. GL

      www.fordparts.com
       
    13. swshawaii

      swshawaii Explorer Addict

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    14. bar422

      bar422 New Member

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      I seen that one from EF and was hoping it went into more detail about pulling the intake but it didn't.Mine is exactly like that one and I have done everything listed but was looking for detailed pics of the intake removal if anyone has them......thanks for all the replies and anymore would be a big help!
       
    15. Big-E

      Big-E New Member

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      I dont know if you fixed this yet or not but i replaced mine with the intake still installed. It didnt take to long as we pretty easy with the right combo of extentions and swivels. Hindsight being 20/20 i should have removed the intake since i just had to replace my vavle cover gaskets and intake manifold a couple weeks ago. But if you want to replace the T-stat housing w/out pulling intake it can be done.

      Good luck
       
    16. bar422

      bar422 New Member

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      Well I have finally figured out how to get the intake off to get to the thermostat housing. Thanks to all who replied...it turns out there were a couple of bolts I was missing and thats why it wouldn't come off.

      Now I have another problem.........does anyone have a rubber tee that goes on the end of the intake manifold hose. This rubber tee has 3 hoses all connected together. The Ford part number is 97 JZ9P904AG. If you get it through the dealer it is very expensive and only comes with an intake hose that I don't need. Any help with this would be greatly appreciated!
       
    17. crazymind

      crazymind Active Member

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      Is on the back or front of the engine? If it the back one its the pcv lines if its the front its for the evap system. The one for the evap I broke and just supper glued it back together with the pcv you can make a new one if need be for much cheaper than the dealer will sell it for
       
    18. bar422

      bar422 New Member

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      It is on the front just behind the throttle body. It is a rubber piece that 3 hard plastic hoses come together.The hose that is not connected anymore goes into the air hose up by the air filter box. I had to move the explorer after this broke and didn't get any lights indicating a problem so I'm not sure how big of a problem this really is? Anymore input will help.
       
    19. J_C

      J_C Active Member

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      You might not get any lights till it warms up enough for the ECM to go into closed loop mode.

      Did it break or was it lost? If it broke you might be able to temporarily hold it together with rubber cement, long enough to cover the outside with caulking to fortify the ripped area.

      Otherwise, possibly you can seek a *generic* vacuum t connector, maybe on ebay or an auto parts store once you know the vac tube diameters. Examples,

      http://motors.shop.ebay.com/i.html?..._Truck_Parts_Accessories&_odkw=&_osacat=38634

      http://www.autozone.com/autozone/ac.../N-25ry?counter=31&itemIdentifier=380212_0_0_



      Another possible option is to get some rubber tubing with an inner diameter marginally smaller than the outer diameter of the hard vac lines, slip a piece of that over each vac line, then the rubber tubing will allow using the more commonly found hard plastic T connectors (or of course, replace the entire length of all 3 hard plastic vac lines with rubber hose, thick enough it won't collapse under vacuum).

      http://www.autozone.com/autozone/ac...ment/Vacuum-Connector-Universal-Type/_/N-25tf
       
    20. bar422

      bar422 New Member

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      The rubber piece was torn completely off so now there is a hole in the spot where it was connected about the size of a quarter. I think another tee would be the best but is there any pressure in these lines? I don't think there is but I'm not sure. I am looking at the one from AutoZone and it looks like it would work the best. The hose is about 3/4 around that is on the explorer.

      BTW.....I tried to drive the explorer earlier and it runs really crappy now and stalls easily so obviously I need to repair the hose. Anymore imput would be great.
       
    21. J_C

      J_C Active Member

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      ^ bar422, a picture might help, I don't quite understand what you mean. Which engine is it?

      There's a quarter sized hole in the air intake tube? You asked about pressure in the lines but they should be vacuum lines, a little easier as they don't push themselves apart but any connector fitting or hose has to have stiff enough walls to withstand the vac level (I don't know the specs for that)... but just about anything would work, standard plastic tees or hose from an auto parts store.

      If all else fails, pull the part at a junk yard. My X has the 4L SOHC engine, if that's what is in yours (and it didn't change) I can take a look at mine for comparison purposes.
       
    22. bar422

      bar422 New Member

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      I went to the parts store today and got a tee and some heavy duty hose and this should take care of it. I will let you know how it goes. Thanks!
       
    23. bar422

      bar422 New Member

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      Well I was able to replace the thermostat housing today and put it all back together and it doesn't even leak!........Thanks again to all those who helped out with their posts........ now to the next problem I found today........I will be starting a new post shortly.
       
    24. mistert2

      mistert2 New Member

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      I have a 2000 explorer 4x4 4.0 V6 with a busted lower thermostat housing and I just found this thread. Biggest problem was finding part and because mine has the screw in sensors and the screw studs are different.

      MUCH help... thank you. I have most of my answers. The only thing I was worried about ... which is now hindsight... was whether to take off manifold. But now that I have, is it okay to just rebolt manifold backon (without a new gasket) after replacing the thermostat housing? I know there is a sequence.

      Is there anything anyone has encountered that they can add to this.
       
    25. swshawaii

      swshawaii Explorer Addict

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      Too late for this improved OEM lower housing upgrade?

      http://www.explorerforum.com/forums/showthread.php?t=239493
       
    26. mistert2

      mistert2 New Member

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      No, not too late swshawaii
      Thanks for the thread link
      http://www.explorerforum.com/forums/showthread.php?t=239493

      I have located the part I need but I have to buy the upper and lower assembly. But includes the sensors with thermostat and gaskets. My cost is $160.00.(Oreilley Auto)

      I think that is reasonable considering entire unit and OEM. YOU THINK?

      However I do like the upgrade option. Just have not commited yet. I think I will check on latest upgrade parts prices and compare. Is the upgrade better than OEM or just because price and availabilty of OEM part?
       
      Last edited: September 17, 2012

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