Rust stains on block around thermostat housing?

Tiny
CFRUSH1
  • MEMBER
  • 2003 LINCOLN TOWN CAR
  • 4.6L
  • V8
  • 2WD
  • AUTOMATIC
  • 85,000 MILES
Water leak troubleshooting pictures attached.
Can I fix it myself?
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Wednesday, March 12th, 2025 AT 3:38 PM

20 Replies

Tiny
KEN L
  • MASTER CERTIFIED MECHANIC
  • 51,530 POSTS
Yep, this is a gasket or the cross over from the thermostat housing. The intake will need to be loosened and propped up slightly.

Here is a video to show you what you need to do:

https://youtu.be/N3Iqjo2jhdc?si=lBFLaJ3nWnlmYXMl

Please let us know what happens.
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Thursday, March 13th, 2025 AT 9:02 AM
Tiny
CFRUSH1
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Hi Ken,
What do you mean that the intake needs to be propped up slightly?
Do I use gasket maker or buy one?
I will see if I can fix it myself, should be fun.
Thanks,
Charlie
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Tuesday, March 18th, 2025 AT 2:43 AM
Tiny
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It appears that the crossover is part of the intake on my Town Car.
Do I just replace the new intake or can this one be fixed?
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Tuesday, March 18th, 2025 AT 3:08 AM
Tiny
KEN L
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I would get a new intake, I would check amazon, here is one for $125.00:

https://amzn.to/3Rib3oe

Let me know how it goes.
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Tuesday, March 18th, 2025 AT 9:44 AM
Tiny
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I will order it.
Can you provide me replacement instructions?
Thank you Ken
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Tuesday, March 18th, 2025 AT 10:59 AM
Tiny
KEN L
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Sure here is how to change out the intake manifold and the torque specs and sequence as well. Check out the images (below). Let us know if you need anything else.
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Tuesday, March 18th, 2025 AT 11:07 AM
Tiny
CFRUSH1
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Hello Ken,

I removed the thermostat housing and there was "no thermostat or O-ring" installed.
Surprise.
I will install new ones with a little gasket maker and see if that works B4 replacing the intake manifold.
I will let you know if it is fixed.

Thanks for the advice,
Charlie
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Wednesday, March 19th, 2025 AT 2:14 PM
Tiny
KEN L
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Yep, they kind of need the thermostat and gasket, let me know how it goes, have a good weekend.
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Friday, March 21st, 2025 AT 8:15 AM
Tiny
CFRUSH1
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Hi Ken,

I now have a DTC code P0205 Cylinder 5 injector malfunction.
Maybe caused by the leak?
Any advice?

Thanks, and have a good weekend yourself,
Charlie
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Friday, March 21st, 2025 AT 10:32 AM
Tiny
KEN L
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Sorry, we only handle one problem per thread, please post your new question here, you must be logged in.

https://www.2carpros.com/questions/new

Did you get the coolant leak fixed?
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Saturday, March 22nd, 2025 AT 10:34 AM
Tiny
CFRUSH1
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Thank you
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Saturday, March 22nd, 2025 AT 9:37 PM
Tiny
CFRUSH1
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Hi Ken,
I am ready to install the new intake.
Do I need to reuse the foam cover on the bottom?
It is kind of falling apart.
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Wednesday, April 2nd, 2025 AT 7:25 AM
Tiny
KEN L
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Can you upload an image so I can see what you are talking about?
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Wednesday, April 2nd, 2025 AT 10:58 AM
Tiny
CFRUSH1
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I guess this is called a heat barrier and noise suppressor.
I taped it up so I will use it.
I guess the part is discontinued.
Also, image of part that failed (plastic channel broke off) and leaked.
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Wednesday, April 2nd, 2025 AT 12:41 PM
Tiny
KEN L
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Yep, that is a heat soak barrier, it should be good the way you repaired it. Also, thanks for uploading the coolant leak problem, once you get the engine back together the problem should be fixed. Let us know if you need anything else, we are here to help.
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Thursday, April 3rd, 2025 AT 9:28 AM
Tiny
CFRUSH1
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I am going to finish up putting parts back in today,
Hopefully it will start up and run well again.
Thank you Ken
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Thursday, April 3rd, 2025 AT 11:09 AM
Tiny
KEN L
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I have confidence you can complete the job and get back on the road! Let me know how it goes and have a good weekend!
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Friday, April 4th, 2025 AT 9:39 AM
Tiny
CFRUSH1
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Got the job completed yesterday and it runs much better without any leaks.
Check engine soon amber light is on.
I will try to see what it is for.
Thanks for your help Ken
have a good weekend yourself,
Charlie
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Friday, April 4th, 2025 AT 11:54 AM
Tiny
KEN L
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Nice work :) please start a new thread if you have other problems, we are happy to help.
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Saturday, April 5th, 2025 AT 10:36 AM
Tiny
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Thank you Ken for all the help,
Charlie
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Saturday, April 5th, 2025 AT 4:26 PM

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