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Old 07-05-2008, 08:17 PM   #1
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zetec thermostat housing leaking

i hear this is pretty common. a friend of mine has a 03 zetec that started heating up the other night, we got to looking and the thermostat housing is leaking where it meets the block next to the coil pack on top of the housing. now i took the plastic cover off of my svt and it has a composite housing with a temp sensor in the top of it. his housing is aluminum without the sensor. my questions are: a. what would be the best route to fix this problem? b. would it be better to replace the entire housing with a composite version from an svt? c. would it be better to just replace the o-ring and hope it doesnt happen again? i would think the aluminum would pit over time due to the fluid inside heating and cooling all the time. the composite shouldnt have this problem. thanks for any input.


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Old 07-05-2008, 08:24 PM   #2
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What I would do is call up Mike at Hilbish Ford and he'll send you everything you need for the repair. According to him that part has been revised and the new one will not crack. It's something like $40 if I remember right.

Also, keep an eye on oil leaking from your valve cover gasket. 99% of the time that is what causes your problem.
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Old 07-05-2008, 08:38 PM   #3
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I went to a junk yard and found a housing that didn't have the leaky valve cover dripping into it and took it off for $15 and I was done with it. Like DCL said though 99.9% of the time the cause is from a leaky valve cover dripping into the housing causing it to corode. So your going to want to get a new valve cover and this housing.
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Old 07-05-2008, 11:25 PM   #4
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the valve cover doesnt seem to be leaking. the block is clean as a whistle on that side. is the revised part composite like the svt?
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Old 07-05-2008, 11:31 PM   #5
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I'm not sure what you mean. It's pretty beefy plastic. Call up Mike at Hilbish and he'll talk to you about it, he knows more about that stuff than anyone else here. I'm pretty sure he'll just sell you the revised housing and a gasket though.

EDIT: I just noticed you had an SVT haha. OK, so my housing is just a beefy plastic. You still need the SVT one I think. They are weird and have some sort of plug on the bottom. But like I said, talk to Mike on the phone. He knows a lot about this stuff and is a very nice and helpful guy.
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Old 07-06-2008, 01:12 AM   #6
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maybe you didnt read my first post. the friends car is the one with the problem. not my svt. the svt has a temp sensor in it. the regular zetec doesnt. the zetec one looks to be aluminum or something whereas my svt's is composite black plastic. what i want to know is if the new revised housing is composite plastic and if not should he just get one off an svt like mine and plug the sensor hole? or would he be better off just getting a new gasket and keeping his housing? ill see if i can pm mike about it
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Old 07-06-2008, 10:20 AM   #7
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^^ Who reads posts anyway?
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Old 07-06-2008, 11:45 AM   #8
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OK I guess I missed the part where you're fixing your friend's car...
I've never seen an aluminum housing. That's pretty weird. The new revised part for the ZX3 is just a really tough plastic. I wouldn't go swapping in a SVT one because they are prone to leaks from that plug too.
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Old 07-06-2008, 11:55 AM   #9
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ok gotcha
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Old 07-06-2008, 12:18 PM   #10
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Aluminum? Really?
Can someone get me a part # for that?


If it is AL just a new gasket would be needed. Personally I'd just use gasket maker on it.
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