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I'm getting this leak as well. I took it to a shop and told me that I had to get a new housing and with labor it would be like $130. Where can I get these o-rings and what material are they? Thanks a lot for any help.
 

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Anybody got the part number for this? Yeah it'll likely leak again, but if its not for another 50,000 miles, I don't mind.
 

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Do you have to drain the coolant when doing this? If not, doesn't that leave air in the system?
The coolant system has two "bleeder" hoses designed to take air out of the system. One of them is on the top of the thermostat housing, the other is on the passenger side top of the radiator. So don't worry about it.
 

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Good post, I'll reference it again in the spring when I fix this myself.
 

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I just started to develop this problem I believe. I noticed a week ago my coolant was low, so I topped it off. I will see if has dropped at all for any reason.
 

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If you can see what color yours has, add the same type, green or possibly yellow. Do not use the orange DexCool for GMs.

Sidenote: The proper size O-ring to use is actually a METRIC o-ring. Remember that Ford converted all its cars to Metric, not to mention the Focus was originally designed in Europe, where metric is the standard. After reading some people used #203 and some used #202, I checked into the metric's and there happens to be a standard metric size right between a #202 and #203. Its a 7mm ID, 13mm OD, 3mm cross-section. I got mine in Viton and of course have some left over. It went back in easily and haven't had a leak since. If you need one, PM me and I'll drop one in the snail mail for you.

Sorry, I'm now out of the o-rings I bought, they can be ordered from places like McMasterCarr.
 

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brawls43, I sent you a pm.

I have been seeing liquid under my car for the past few days and a faint smell of coolant while driving. Checked under the hood and sure enough the plug is leaking and the coolant level is a wee bit low. I may go ahead and get a 180 degree thermostat while I`m at it.
 

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just did my t-stat housing last weekend. i was given an estimate of $250. decided to do it my self. bought the housing, t-stat and the t-stat o-ring. took about an hour. i didn't need the t-stat, the original was in perfect condition and the o-ring was also, so just buy the housing. i used alittle silicone on the housing where it meets the block incase it cracked agian.
 

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If you can see what color yours has, add the same type, green or possibly yellow. Do not use the orange DexCool for GMs.

Sidenote: The proper size O-ring to use is actually a METRIC o-ring. Remember that Ford converted all its cars to Metric, not to mention the Focus was originally designed in Europe, where metric is the standard. After reading some people used #203 and some used #202, I checked into the metric's and there happens to be a standard metric size right between a #202 and #203. Its a 7mm ID, 13mm OD, 3mm cross-section. I got mine in Viton and of course have some left over. It went back in easily and haven't had a leak since. If you need one, PM me and I'll drop one in the snail mail for you.

Sorry, I'm now out of the o-rings I bought, they can be ordered from places like McMasterCarr.

I just did this, and ordered the metric oring from mcmastercarr. I looked around at all the local automotive parts shops, even a few 'specialty' shops that I was told might have metric o-rings, with no luck.
After getting the o-rings, I switched mine out in about 10 minutes. The metric o-ring fits really well without having to force it. about 1/2 gallon of coolant comes out, but it's a fairly quick switch.
 

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I just replaced the whole housing..... the large or ring where it seals to teh head was blow, the plasctic had cracked. 102$ from ford for a new new one, while i was in there I also repalced my leaky valve cover gasket... this was an easy job though only took an houe to do both, thanks FF
 

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my 2000 ZX3 is bleeding coolant and the thermostat housing is drenched. how can I determine what the cause of the leak is?

does the 2000 ZX3 have this plug?
what replacement parts should i have on-hand if i am going to attempt a fix?

thank you,
jSV
 

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my 2000 ZX3 is bleeding coolant and the thermostat housing is drenched. how can I determine what the cause of the leak is?
If it's coming from the housing, it is probably a cracked housing or bad gasket.

[/QUOTE]
does the 2000 ZX3 have this plug?
what replacement parts should i have on-hand if i am going to attempt a fix?
[/QUOTE]

I don't think it has the plug. but i could be mistaken.

New housing, gasket and thermostat (Hoses to, depending on how bad yours are degraded). Take the housing off and verify it is not cracked. Take care to check the gasket for any abnormalities.

That's how I would start.
 

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i'm now getting a coolant leak on my 2003 Zetec. I changed my battery last week and noticed the coolant was low, so i topped it off. Today I pulled out of the driveway and noticed what looked like a like spot. When I got back home, I popped the hood and sure enough the coolant reservoir was damn near empty after only a week or so.

I got a little confused reading this thread. So only the SVT's have the plug with the O-ring?? What do I need to do to fix the leak on a Zetec? And i'm a total newb to DIY'ing, so saying thermostat housing means nothing to me. lol Any pics of this process on Zetec like JohnMichael provided for the SVT?

Thanks in advance.
 

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I just did this fix today. Remember that there is no such thing as too much o-ring lube.

So for under $20 and an hour of time I saved $550, which is what Bonnell Ford wanted to replace the thermostat housing. This of course wouldn't have fixed the problem.

FYI, I have a 2003 with 80k miles on it.
 

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I had to order the whole plug from Ford as the o-ring wasnt sold seperately. It will be here on Tuesday and I get to have "fun" tackling it.
 
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