Dismiss Notice

and gain access to Reviews and Discussion of the 2016 and 2017 Ford Explorer Tech Tips, How to Articles, Off-Road Modifications and Events, Street Truck Mods and Events, and much more! Since 1996 our community has covered every aspect of the Ford Explorer, Ford Ranger and all vehicles based on this platform.

Register Today It's free! This box will disappear once registered!

How to: Replace a thermostat on a 2000 4.0L SOHC V6

Discussion in 'Stock 1995 - 2001 Explorers' started by AeroRamer, January 23, 2011.

  • Searches ExplorerForum.com
    1. AeroRamer

      AeroRamer Member

      Joined:
      July 17, 2008
      Messages:
      84
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Jax, FL
      Year and Model:
      '00 Limited
      The following write up is for informational purposes only. This is just an account of what I did while troubleshooting an overheating anomaly (see thread here) on my 2000 Explorer Limited. As part of my T/S I removed the thermostat and took some notes and pictures along the way. I was not sure how involved this was going to be but it end up been very straightforward. It took me about 1.5 hours total to do this and another 15 minutes or so to test drive the Ex. Here is what I did:

      Please note that this write up is for the removal and replacement of the thermostat for a 4.0L SOHC. The write up for the 4.0L OVH was done by 'Charlie' and can be found here.

      Tools needed:
      -Ratchet
      -8mm socket
      -10mm socket
      -9/32" socket (the 7mm was a bit smaller and the 8mm to big)
      -Pliers
      -Paper towels or rag
      -Small brush to scrape off some gunk and debris

      First off, when I checked the repair manual, it said to drain the coolant out of the car. I did not have to do that. Since the thermostat sat on top of the block I thought that if there was some coolant it would be the coolant inside the upper hose, and that it would be minimal. So, I decided to go on very carefully without draining the coolant.

      With the engine cool, using a ratchet and a 9/32" socket, I removed the four screws holding the plastic engine cover in place.
      [​IMG]

      Next, using an 8mm socket, I loosened the clamp holding the air filter duct enough to be able to slide it off the intake body. After removing the electrical connector, and the two hoses that connected to it I removed the air filter duct from the Ex.
      [​IMG]

      [​IMG]

      [​IMG]

      [​IMG]


      Using a 10mm socket I removed the top wire from the alternator (not sure if that is the ground or current and I did not check). I did this to get better access to the thermostat housing and the upper hose clamp. I also found it easier to work when I removed the electrical connector from the intake body.
      [​IMG]


      Using a pair of pliers, I moved the clamp holding the upper hose to the thermostat housing out of the way. To move the hose out of the way I removed the 8mm screw that hold the hard plastic section of the hose to the engine block.
      [​IMG]


      With everything out of the way there is now enough area to remove the three (3) 8mm screws that secure the thermostat housing. Note that there are only three screws and not four like I thought. Removing the housing cover give you direct access to the thermostat. To remove it just pull on it. I think I've read t that it is a good idea to notice the orientation of the thermostat and to install the new one in the same position. I am not sure about that but I did it anyway.
      [​IMG]

      [​IMG]


      Before installing the new thermostat and gasket, using a couple of paper towels and a small brush, I cleaned both sides of the housing to remove gunk and loose debris. From the pic below you can see the discoloration from coolant that may have leaked from the hose or the housing.

      Once the new thermostat and gasket was in place I re-installed everything in reverse order. Bleed (burp) the air out off the system and fill with coolant/water as needed.

      Below is a pic of the old thermostat (left) and the new one (right). After a quick visual inspection I could not tell if he old thermostat was bad. One difference between both thermostats was the temp rating stamped on them. The old one (DFT) was rated to 197/223 degrees Fahrenheit versus 190/??? degrees for the new one (Stant, P/N 13649).
      [​IMG]

      [​IMG]
       
      Last edited: April 24, 2011
    2. Support EF


      Join the Elite Explorers for $20 a year

      Explorer Forum has probably saved you that much already, and will continue to save you money as you learn how to diagnose and fix problems yourself, and learn which modifications work without having to experiment on your own. Elite Explorer members see practically no ads, add your own profile photo, upload photo attachments directly to your posts and Media Gallery, create more private Conversations, and more. Join Today. Your support is greatly appreciated.



      to hide adverts.
    3. section525

      section525 sextion525 Staff Member Moderator Elite Explorer

      Joined:
      February 11, 2001
      Messages:
      14,786
      Likes Received:
      1
      Trophy Points:
      0
      City, State:
      Red Bluff, Ca
      Year and Model:
      1975 Ford Bronco 4x4
      Awesome write up! You V6ers have it so easy!! :D
       
    4. ucluglee

      ucluglee Member

      Joined:
      October 13, 2010
      Messages:
      84
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Greenville, SC
      Year and Model:
      '00 XLT
      Very nice. I should have documented when I replaced my thermostat housing, but it was 28 degrees outside and I wanted to get is done and back in the house.
       
    5. AeroRamer

      AeroRamer Member

      Joined:
      July 17, 2008
      Messages:
      84
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Jax, FL
      Year and Model:
      '00 Limited
      Glad you all like it. Just doing my part to help others as others have helped me in the past. It was a toasty 45 degrees here in North Florida. Needless to say it was too cold for my taste. I was trying to work as fast as possible to avoid working at night.
       
    6. Hogitall

      Hogitall New Member

      Joined:
      January 30, 2011
      Messages:
      22
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Austin
      Year and Model:
      98 XLT
      My dilemma is that the thermostat housing keeps pushing the rubber o-ring gasket out of place and outside the sealing area (which I'm assuming you push it over the lip on the underside of the housing out towards the holes?) it keeps pushing out out of the sealing area when I try to tighten it down. Am I doing something wrong ?? Am I placing the o-ring gasket in the wrong place? And should I use gasket sealer? HELP!!
       
    7. 2TimingTom

      2TimingTom Well-Known Member

      Joined:
      October 12, 2010
      Messages:
      2,376
      Likes Received:
      8
      Trophy Points:
      48
      City, State:
      Highlands Ranch, Colorado
      Year and Model:
      '97 XLT
      This good:
      [​IMG]

      This bad:
      [​IMG]
       
    8. Hogitall

      Hogitall New Member

      Joined:
      January 30, 2011
      Messages:
      22
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Austin
      Year and Model:
      98 XLT
      OK..I think I have it now...Gasket placement issue..Hopefully it's good to go now..
       
    9. jmazz8

      jmazz8 New Member

      Joined:
      December 30, 2009
      Messages:
      17
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      southington, ct
      Year and Model:
      2010 Explorer Eddie Bauer
      thanks for the help

      Directions were very helpful...
      I have a 1999 Explorer Sport and the layout is nearly identical.
      Thanks!

      :thumbsup:
       
    10. LaRue

      LaRue New Member

      Joined:
      March 20, 2011
      Messages:
      1
      Likes Received:
      0
      Trophy Points:
      0
      Year and Model:
      '99 Eddie
      I feel like a man again

      Dude, Thanks for the how-to instructions. You saved me over a hundred smacks, drew in the neighbors with the hood up and the echoing rachet sound, and made me feel like the all-american macho male again. :usa:

      I'm looking forward to the next project!
       
    11. stevebr

      stevebr New Member

      Joined:
      April 16, 2011
      Messages:
      1
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Washington
      Year and Model:
      2001 SportTrac
      Yea! Your instructions helped!

      I had just about given up. Went online and found this forum. Your instructions were great. The bolt holding on the plastic radiator hose bracket was what was holding me up. Thank you.

      One comment. I think the wire you unbolted from the alternator was the Poistive side, not ground. I disconnected my battery before removing it for safety. Now I have to reset the radio stations! Bummer.

      Thanks again.
       
    12. 6iron

      6iron New Member

      Joined:
      April 19, 2011
      Messages:
      10
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Toronto, ON
      Year and Model:
      '00 XLT
      I wish mine was that easy... unfortuantely, a few months ago (for no good reason, of course), the hose connection on the top of the stat housing broke while on the highway. Coolant gone in about 1.3 seconds, and a lot of it hit the fan, so it was everywhere.

      Replacing the entire housing was awful - they really don't design these to ever be taken apart again... getting at them is 75% of the work.
       
    13. AeroRamer

      AeroRamer Member

      Joined:
      July 17, 2008
      Messages:
      84
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Jax, FL
      Year and Model:
      '00 Limited


      Glad I could be of service. I just uploaded the pictures to the forum so they are here permanently.

      Thanks for the correction stevebr. I changed the sentence.
       
    14. AeroRamer

      AeroRamer Member

      Joined:
      July 17, 2008
      Messages:
      84
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Jax, FL
      Year and Model:
      '00 Limited

      For me it just fell in place. I did paid attention to the way the old one was oriented and installed the new one the same way. Maybe you are tightening to hard and pressing the o-ring out(?). Are you sure it is the one for your Ex?
       
    15. Matie

      Matie Member

      Joined:
      November 21, 2007
      Messages:
      95
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Abu-Dhabi UAE
      Year and Model:
      Explorer 2003 & XLT 96
      Good Write -up Mate!

      Just a question, I live in UAE , HOT HOT weather, most of the peoples just take of thermostate , what is the side effect, or it works fine,
      My Fordy 96 had some problem in last winter,( when we say winter its mean around 22 to 26c somewhere!) so Garage changed Thermostate , now , in hot days tepmerature is normally statys above the middle , which is ok, BUT , I have noticed there is bit water leak & around the PLUG area, i dont know if its Cylinder head Gasket? anyway i am thinking to take off TS so car will not get much hot & pressureise the engine!! is this OK??
      secondly how big job is to change that Gasket?

      Regards
      Matie
       
    16. DoctorE

      DoctorE New Member

      Joined:
      June 3, 2011
      Messages:
      4
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Dallas TX
      Year and Model:
      2000 and 2003
      This article is helpful. Thanks.

      Another nice thing to have during this thermostat job is one of those “universal joints” to go with the ratchet drive extender. This will allow you to turn the bolts at a more comfortable angle. Most socket sets include one of these.
       
    17. NorthernRebel

      NorthernRebel New Member

      Joined:
      February 6, 2011
      Messages:
      1
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Lafayette,TN
      Year and Model:
      2000 XLT
      Thanks for the great pics. and instructions. I have a 2000 XLT with the 4.0 SOHC, and the thermostat housing just started leaking and went into overheating in a matter of minutes. I had bought a replacement housing from Advanced Auto. The whole upper and lower housing was manufactured by DORMAN. When we bought the part we showed the parts person that the part had a slight warpage in it. We were told that they all look like that. I had installed it, and in a matter of two weeks it started leaking worse then the original part. A word to the wise "When replacing the Whole Thermostat Housing and thermostat, CAREFULLY INSPECT the whole item where the sensors are installed and where the upper part joins the lower for warpage. And also the manufacture date of your vehicle, because there was a gasket change for vehicles built after 7/24/00. Thanks for all the wonderful info on this forum.
       
    18. Racingtheburg

      Racingtheburg New Member

      Joined:
      February 7, 2011
      Messages:
      25
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      St. Petersburg, FL
      Year and Model:
      1997 Limited
      Mine was not this easy to access and I took the upper intake off to look for leaks and really easy access to the thermostat.
       
    19. bar422

      bar422 New Member

      Joined:
      September 4, 2010
      Messages:
      20
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Ia
      Year and Model:
      1997 Explorer XLT
      Hey Racingtheburg......how did you get the intake off? I have to replace the thermostat housing in my 97 and am trying to figure out how to get it off without wrecking anything.
       
    20. Racingtheburg

      Racingtheburg New Member

      Joined:
      February 7, 2011
      Messages:
      25
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      St. Petersburg, FL
      Year and Model:
      1997 Limited
      There are a couple of bolts and hoses. When you take the hoses off a good trick is to get the blue or bright green painters tape and put a piece where you took the hose off and number it 1 and put a piece on that hose that went there and label it 1 with a permanent marker. Keep doing this for all the hoses and even bolts it will make your life easier and I cant remember half the time what I did 2 hours ago lol.
       
    21. chaliceburn

      chaliceburn New Member

      Joined:
      September 30, 2011
      Messages:
      6
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      anchorage, alaska
      Year and Model:
      2001 Explorer
      I can tell you how *not* to do this repair.

      I did this job about three times in a row on my 2001 6cyl SOHC. First, they gave me the wrong thermostat, which I didn't realize because I hadn't taken it apart yet.

      Then they said that the right thermostat didn't come with a gasket (in my case a simple rubber o-ring), so I decided to reuse the one already on it. It had slight damage but was reasonably intact. Drove it and pissed water all over the belt, fan, everywhere.

      So I decided to half-ass it and slapped RTV all over the outer housing. Lasted about a day before it sprang a leak.

      Then I got a new o-ring gasket and put it on, plus more even thicker layers of RTV, thinking that was the culprit. Nope. Peed all over yet again.

      Finally I got a new plastic housing because the parts guy thought maybe I'd overtorqued the three screws and maybe cracked it. He was almost right. After taking my time (and scraping off a ton of RTV) and actually *looking everything over*, I noticed a tiny chip in the old housing 'lip' that sits on top of the o-ring. Right where it was pissing water. Duh.

      moral of the story: take your time, pay attention to all the parts involved. No idea how that tiny chip got there, but that was definately the problem.
       
    22. JRock10

      JRock10 New Member

      Joined:
      March 17, 2007
      Messages:
      17
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Nashville, TN FTW
      Year and Model:
      2000 Eddie Bauer
      Thanks for this write up! I just got done replacing the thermostat on my 2000 EB 4WD. Piece of cake with all your photos!
       
    23. JonAlthoff

      JonAlthoff New Member

      Joined:
      July 18, 2008
      Messages:
      9
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Canal Winchester, OH
      Year and Model:
      2000 Sport
      replacement thermostats and upper housing leaks

      So around a year or 2 ago the water pump gave out and I replaced it. I had problems with leaks and figured it was the water pump but turned out that the lower thermostat housing was deteriorating. I replaced that and hoses and everything was fine. Last weekend coolant started spraying everywhere and I found the house going from the housing to the heater burst. The thermostat (new one from the replacement Dorman housing) wasn't opening and caused the overheating. I picked up a new thermostat and then the hose. The flange on the outside edge of after market thermostat is half of the size of the Dorman thermostat. I'm having all kinds of issues with leaking at the seam of the lower and upper housing. I'm not sure if I am tightening the upper housing to the lower housing too tight. We made an aluminum spacer but that is not helping either. We took a look at the upper housing and it appears to be warped. I picked up a new one and am hoping to install it here in a few minutes. I have also replaced both of the 13 year old temp sensor/sending unit

      Any other suggestions? I had used the old gasket and the new gasket before trying the custom made spacer and that worked the best so far but still was leaking. I'm wondering if I could find a larger in diameter gasket...

      2000 Explorer 10/99 up to 283k miles

      *** as an update the upper water outlet housing was warped. Replaced with new and tightened down a little at a time and tested leaking before I had it tightened down all the way. So far so good 10/4/12.
       
      Last edited: October 4, 2012
    24. Enginerd

      Enginerd New Member

      Joined:
      July 31, 2013
      Messages:
      1
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Hales Corners WI
      Year and Model:
      2000 Ford Explorer XLT
      Ooooh, I'm glad I found this! My Green Beast has started to have some overheating issues (not bad for a 13-year old) and this is something I will have to try.
       
    25. Dead_Goldstar

      Dead_Goldstar New Member

      Joined:
      December 5, 2010
      Messages:
      38
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Winnipeg, Manitoba
      Year and Model:
      2005 FORD EXPLORER SPORT
      The write up and pictures are amazing really help with changing my thermostat on my 2005 Ford Exp sport tract. It's great to have a forum where every one is willing to help others out with there issues and give such detail on how to do repairs. This is truly a great site to be part of just wanted to thank every one for the help and assistance I have received from this site.
       
    26. LWM968

      LWM968 New Member

      Joined:
      April 8, 2013
      Messages:
      1
      Likes Received:
      0
      Trophy Points:
      0
      Year and Model:
      2000 Explorer 4.0L
      Thermostat and AC are connected

      First I found this post very helpful in replacing my 2000 Explorer 6 Cyl thermostat. My first indication that the thermostat was bad was when the AC stopped working. In Texas in July that's a serious problem. It turns out that when the engine temp reaches a certain point the computer shuts off the AC.
      I found this out after having a leaky AC hose replaced and Freon added but by the time I had driver around more that 15 minutes the AC stopped working again. Replaced the thermostat and problem solved.
       

    Share This Page


    Click Here

    We Support Our Troops!