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Lower T-stat...

Joined
April 24, 2014
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City, State
South Florida
Year, Model & Trim Level
02 EXPLORER /'90 Mustang
Early May 2014, I walked up on my '02 Explorer backed into a Freshly Paved Asphalt Parking Spot. As I walk up & get closer to my Ride a Smile :D Turns to :( When I saw not only the normal A/C puddle, but a second puddle 12" in front of the normal A/C Puddle and with the unmistakable smell of Coolant. "OH ****" I whisper to myself. As I take a knee & look under my 4.0L SOHC powered Explorer I felt the Oily Substance of coolant between my finger tips and felt myself get a bit :mad: because In April I had just finished replacing my 3rd Master Window Control Switch, Fixed Driver's Window with all New Parts, Then the Spark Plugs (.054 Gap BTW) I had also replaced the (6) made to spec. Motorcraft 8mm Spark Plug Wire Set as well as the Fuel Filter and I found a Pesky Faulty Alarm door Ajar switch in the Front Passenger Door. I jumped the two door Ajar swith wires and the Alarm was back to working order. Anyway I Got Her Home Safe in my Carport. The Next Day I Started with a Investigation Of the Usual water pump, t-stat, Ect. Suspects. When I Found (2) Leaks. A :salute: To the Duel Leak find & to this forum for signs on what to look for on the 4.0L. So Far "In My Opinion" This Forums wealth of Knowledge it Possesses has me hooked in adding to it's Existence Today, As a Newbie On Here, I Hope, Some Pics I Will Post may Help Someone Somewhere..Thank You For Reading.
 

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Another Angle the of Aluminum mating surface before a fix

Here is another angle of The Pitting. It's hard to believe that 50/50% Coolant/Distilled water Can wreck havoc To this extent...
 

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aluminum compatible coolant?

I don't recall noticing any pitting on my 2000 when I replaced the thermostat housing. The pitting on your engine is excessive to the point that I wouldn't trust the stock gasket to seal. It may not be wide enough to cover the pitted area. I wonder if there is some type of filler like JB Weld that you could fill the pits with. Is your coolant aluminum engine compatible?
 






Lower T-stat Housing/Aluminum Mating Surface FIX. '02 4.0L

Thanks for the reply 2000StreetRod.
When I had her apart, JB Weld was the only thing I could think of using. And these days I found out that, JB Weld has quite a few choices on the market. I didn't want to go with the JB Welds original formula after reading all of the other choices. So far so good. I have another picture of the finished product I wanted to post.
I wanted to post the pitted picture because, I could not find another picture with this Particular problem...
 

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I forgot to add that, I put a second coat of JB Weld on, after sanding the first with 240 grit sandpaper using a DREMEL. I think I have a better picture but, this is how I fixed my aluminum surface...
 












A dremel attachment

Yeah, DREMEL Came out with this New "EZ-Lock" Mandrel. I saw it at a Hardware store. This Allowed for a screw-less center of 240 grit sandpaper.
The Sanding discs are about The size In Diameter, of the inlet hole. Next time you're in a hardware store, Check them out. 240 grit was the perfect Grit For my application. Oh Yeah, BTW. I Used JB Weld Marine, After returning the original
JB weld formula. I guess it's a personal choice. I just hope, it holds up...
Happy 4th :us:
 






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