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ZETEC Performance (2000-2004) The place to chat about any 2.0L Zetec engine performance, tuning and exhaust related upgrades.

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Old 02-16-2014, 07:04 PM   #1
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Zetec Coolant Outlet housing issue/

Found some info on Wikipedia about the Zetec engine...is there a nice new metal/replacement/better part for the ABS Coolant Housing issue?

....here is the excerpt from the Article:


The 2.0L Zetec engine has seen some issues. Although the block and cylinder head are thermally stable, the coolant outlet housing for the thermostat is not. The housing used in the 20002004 model year US Ford Focus and 20012004 model year Ford Escape with 16-Valve DOHC engine is made from ABS plastic. It is bolted to the surface of the cylinder head on the right side of the engine with three bolts. The mating surface seals to the cylinder head with a rubber O-ring style gasket. The O-ring is held in place by a lip on the housing which is prone to cracking. The immediate inner portion of the housing will exhibit pitting and bubbling. Over time, pieces of the lip will break off, releasing plastic fragments into the cooling system. These fragments have not been known to cause any severe damage to the cooling system but the damaged lip on the housing will cause the O-ring seal to rupture. This allows coolant to leak out onto the upper transmission bell housing. The failure can result in severe loss of coolant.

In 2010, a Focus SVT owner in Minnesota identified a fix for the housing issue. It involves the use of a more durable housing made for an earlier model of Zetecs. The lighter housing (still specified by Ford Parts) has not been corrected for the design flaw. It has a short service life and is the cause of repeated failures. As of September 2013, Ford sells both versions of the housing. The better version lists for $20 more (USA) and has barbed hose fittings, as opposed to the smooth fittings of the problematic fitting. Fixes have been identified for the housing used by the Focus SVT as well as for the simpler housing used by ordinary Foci.


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Old 02-16-2014, 07:32 PM   #2
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Bostig Billet Aluminum Thermostat Housing
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Old 02-16-2014, 08:20 PM   #3
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So there is also a Ford Contour option also?
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Old 02-16-2014, 09:05 PM   #4
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IIRC Contour was a source for aluminum housings from the junkyard, not easy to find anymore.
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Old 02-16-2014, 09:09 PM   #5
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No US zetec never had a metal housing.

Last edited by iminhell; 03-17-2014 at 12:21 AM.
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Old 02-16-2014, 09:28 PM   #6
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Gotcha.

Memory was mixing up aluminum Contour valve covers & the Contour 180 degree T-stat. Put 2 & 2 together & get junk info.
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Old 03-15-2014, 05:57 PM   #7
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I use the stat housing for '98 Contour zetec on mine, the good bakelite one with equal spacing on the cover bolts rather than the crap later ABS housing that sucks so bad. I put ABS one on from Autozone and it leaked like a sieve brand new, the cover flexed rather than pull the o-ring tight. Right in the big space where the cover bolt is missing for so long a stretch. The cover flexes there from the molded in notch and no bolt there. The fool engineer that designed that should be shot.
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