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Discussion Starter #1
Have a 2003 ZX3 16v 2.0L Zetec Focus, and I found a leak of radiator fluid coming from the Drivers side of the engine. There is a Square housing that has 1 hose coming off of the top(approx. 1/2in) and 1 hose coming off the bottom (approx. 1 1/2in.) is this the thermostat housing and if not what might it be? Thank You.
 

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IIRC, yes it is the thermostat housing. Made of black plastic, once it cracks, coolant will leak out. There is an oring gasket that seals this assy, but 99.9% chance there is a crack. Relatively easy to remove, surprising affordable from the dealer, plan on a new thermostat and a gallon of coolant.
 

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hey

I found a Thermostat housing kit that came with the new thermostat for only $49, not too bad. Also I inspected the old one and there were no cracks in the housing, but the o-ring inside was torn to pieces and from what, I have no idea. Total time to do this repair was right around 40 min, removing the hoses on the bottom and behind the housing were the hardest part. Thanks again.
 

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Most of the time the failure is do to a leaking valve cover gasket. The oil will work it's way down to the t-stat housing and destroy the o-ring. Every single Zetec engine will eventually have this problem. On mine, the housing ended up cracking right where the o-ring meets the block. I would also change the clamps to the worm type. The factory clamps are a PITA. And they are always put on at an impossible angle to undo.
 

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Yeah I noticed some oil leaking down from the valve cover and now I know why that gasket was so wasted. And your not kidding about the factory clamps.
 
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