The Motorcraft Parts Game

[merlot4]

During an in-town drive the temperature gauge started to go up and the fan came on. By the time I pulled into a lot the red thermometer warning light came on, and I turned the car off. After a 20 minute wait I found no fluids under the car, and upon starting it, it was fine. I was told that it could be a bad temperature sensor....or something else, the Ford place will have to take the car and examine it to find out. Calling to make an appt for this, I was informed by the manager that they have already had two 04's towed in and the needed parts were not available, whatever they might have been. I was further warned that parts for this car are obsolete and not available (from Ford) and that they will not install parts from other manufacturers. While they've done good service in the past, I was less than impressed with this blanket statement, Having just looked, I found the correct Motorcraft temperature sensor with no trouble, so while many parts really are unobtanium, and the list is growing, not all are. I guess it's time to find a quality mechanic here.

[BillyL]

I had a similar event last month with my 04 bird. temperature gauge pegged suddenly, red light came on, and car went into limp mode before I could get off the highway. In my case it was a cracked plastic thermostat housing that caused the thermostat to stick closed. My mechanic found the OEM motorcraft replacement parts online and had then overnighted.

[Gobird]

I would think thermostat I have had two replaced over the years. Just my opinion.

[merlot4]

Billy, I have had that happen twice, the plastic housing is an accident waiting to happen.

[BillyL]

Definitely! and the aftermarket parts such as Dorman are even more unreliable than the OEM. parts. This was my second thermostat housing failure as well. This time I demanded motorcraft parts even if it meant a delay for shipping and cost more. The original one lasted 16 years and the dorman aftermarket part did not make 2 years!

[007Cruiser]

Didn’t someone offer an aluminum housing?

[merlot4]

Didn’t someone offer an aluminum housing?

I remember the same thing, Gene, but don't recall where.

I cannot guarantee this, but it's my understanding that this Jaguar part will fit the 2002 TBird. I"m pretty sure the 2003-2005 housings are different.
https://www.ebay.com/itm/27173181246...6873:g:ENcAAOS wsBtaJcuq&vxp=mtr

The description of this for 2003-05 states metal construction, and a chat with them said the same, but it looks like plastic.
https://www.partsgeek.com/8cpzbp7-fo...-assembly.html

Here's an Amazon page of housings (plastic) to compare, the 2002 looks pretty different.
https://www.amazon.com/s?k=ford+thun...&sprefix=ford+ thunderbird+thermostat+housing+2002-2005%2Cautomotive%2C85&ref=nb_sb_noss

[Brad]

The Dorman thermostat housing is horrible. IMHO the OEM thermostat housing fails due to overheating. I constantly hear stories of owners allowing their cars to repeatedly overheat while they are trying to diagnose the problem. Continue down that path and you will blow a head gasket. One of my Retros still has the original thermostat housing in it and I don't think it's a coincidence that it's never overheated

[merlot4]

Your experience speaks volumes, Brad. In my 2 cases, however, the engine mgmt shut the engine down, so no way to do anything, other than to be towed to the shop. While I'm not advising anyone to purchase any product, the ones I gave links for above didn't seem to be Dorman brand, are these in the same camp?

[Brad]

The metal sounds like a great idea. Never heard of the others, wonder if they are relabeled Dorman.

[BillyL]

My mechanic had voiced concerns about a possible blown head gasket and/or engine internal problems caused by the overheating during the thermostat failure. After repairs, I have not seen any warning signs of further damage. The car runs and idles perfectly, the temp gauge stays steady at midrange. I have put about 250 miles on the car since the repairs, mostly short local trips of 25 miles or less. I have checked the coolant level often since the overheating incident and have seen no loss of coolant. I am still a little hesitant to put the car on the highway for a longer trip, so far just a lack of confidence on my part. Any suggestions of what else I could do other than drive it?