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Looks like a more serious problem- I am now seeing a little coolant in the exhaust. Hopefully just a blown gasket or head problem. We've had the XLT since new and it still is a great vehicle... Thanks to all for the pointers

Another question/comment- Shouldn't the coolant in the overflow tank / resevoir drain or at least siphon back into the radiator if the radiator is low? If the radiator is hot & is low on coolant, I would think that coolant in the overflow tank would siphon back into the radiator as it cools...

Thanks guys for the responses & advice. I have filled and refilled, and have refilled again after it cooled- thinking I may have that one covered. I'll try filling it on an incline w/ the radiator at the highest point to see if that does it. If I do have a head gasket leak (or worse), I am...

Thanks- Wondering if I have something more serious going on. Left it sitting overnight, resevoir still 2/3 full but radiator level was down a couple inches. Topped off the radiator. As engine began to warm, coolant began running out the resevoir. Vented at heater core, had some air then...

Great forum- I've seen a few threads on this but I think I have covered the obvious stuff already. '96 XLT 4.0 4WD w/ about 146K, had it since new. Wife noticed engine running hot, not quite in the red but 'check gage' was lit. Limped home and I replaced the thermostat with a new Stant 195...

Depending upon the amount and depth of rust, you might be able to clean it up via DIY. Look for Norton BearTex or 3M scotchbrite wheels or discs. Black are generally quite coarse, maroon are usually medium. Some are made to fit on a drill, but if you have an angle grinder you can find...