NHTSA Complaint #10241274 — 2002 FORD FOCUS

ON MY 2002 FORD FOCUS, THE THERMOSTAT HOUSING BEGAN LEAKING COOLANT WHEN THE THERMOSTAT HOUSING GASKET AGAINST THE ENGINE BLOCK FAILED. THIS IS A COMMON PROBLEM ON VARIOUS YEARS OF THE FOCUS AS VERIFIED BY THE COMMENTS OF THE FORD MOTOR CO. PARTS SALES PEOPLE IN SAYING THAT THEY SELL MANY OF THE THERMOSTAT HOUSINGS, AND ALSO BY BLOGS ON INTERNET CHAT LINES. THE RUBBER GASKET SWELLS WHEN IT COMES IN CONTACT WITH OIL AND BREAKS OFF THE INNER GASKET-SUPPORT RING, ALLOWING THE LEAK TO HAPPEN. IT IS A POOR DESIGN THAT CAN LEAD TO MAJOR PROBLEMS SUCH AS ENVIRONMENTAL POLLUTION AND ENGINE FAILURE. I WOULD BE GLAD TO MAIL THE AFFECTED PART TO YOU FOR YOUR EXAMINATION. IT IS AMAZING HOW COMPLETELY THE SUPPORT RING FAILED, AND THE CONDITION OF THE GASKET THAT IS NOT COMPATIBLE WITH OIL WHICH LEAKS FROM THE VALVE COVER ABOVE. THE PART COULD EASILY BE REDESIGNED TO USE A STANDARD O-RING FOR THE SEAL, WHICH IS RESISTANT TO OIL, AND SEALS BETTER. THE CURRENT GASKET IS MORE LIKE A RUBBER BAND THAT IS HELD IN PLACE BY THE INSIDE RIM WHICH BREAKS OFF. *TR