Dorman 902-1038 Engine Coolant Thermostat Housing Instruction Manual for Ford Models

Introduction

This manual provides essential information for the Dorman 902-1038 Engine Coolant Thermostat Housing. This component is designed as a direct replacement for the original thermostat housing on specified Ford vehicles, ensuring proper fit and function within the engine's cooling system. It is engineered to withstand extreme temperature changes and resist common failures such as cracking and leaking, offering a durable and reliable solution.

Product Overview

The Dorman 902-1038 is an engine coolant thermostat housing assembly. It includes the housing unit and a gasket for proper sealing. This part plays a critical role in regulating engine temperature by controlling the flow of coolant.

Image 1: Front view of the Dorman 902-1038 Engine Coolant Thermostat Housing, showing the main body and the included gasket.

Image 2: Side view of the Dorman 902-1038 Thermostat Housing, highlighting its angled design and the gasket.

Compatibility

This thermostat housing is compatible with select Ford models. To ensure proper fitment for your specific vehicle, it is recommended to verify compatibility using your vehicle's make, model, and trim level.

Known Compatible Vehicle Model Years:

• Ford E-150 Club Wagon: 2003
• Ford E-150 Econoline Club Wagon: 1997, 1998, 1999, 2000, 2001, 2002
• Ford E-150 Econoline: 1997, 1998, 1999, 2000, 2001, 2002
• Ford E-150: 2002, 2003
• Ford E-250 Econoline: 1997, 1998, 1999, 2000, 2001, 2002
• Ford E-250: 2003
• Ford Econoline Wagon: 1999, 2000, 2001, 2002
• Ford Econoline: 1999, 2000, 2001, 2003
• Ford F-150 Heritage: 2004
• Ford F-150: 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010
• Ford Lobo: 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008
• Ford Windstar: 1997

Key Features

• Ideal Replacement: Directly replaces the original housing on specified vehicle years, makes, and models.
• Durable Construction: Specifically designed to withstand extreme temperature changes and resist cracking and leaking.
• Cost-Effective and Reliable: Offers original manufacturer quality at a lower cost compared to dealership replacements.
• Industry-Leading Design: Professionally engineered by Dorman, a leader in replacement thermostat housings.

Setup and Installation

Installation of an engine coolant thermostat housing requires mechanical knowledge and specialized tools. It is highly recommended that installation be performed by a qualified automotive technician.

General Installation Steps (Consult a service manual for your specific vehicle):

1. Ensure the engine is cool and the vehicle is safely supported.
2. Drain the engine coolant from the radiator.
3. Locate the existing thermostat housing.
4. Carefully remove any hoses connected to the housing.
5. Unbolt and remove the old thermostat housing.
6. Clean the mounting surface thoroughly to ensure a proper seal.
7. Install the new Dorman 902-1038 thermostat housing with the provided gasket, ensuring correct orientation.
8. Tighten bolts to the manufacturer's specified torque.
9. Reconnect all hoses securely.
10. Refill the cooling system with the appropriate coolant, bleeding air from the system as necessary.
11. Inspect for leaks and test engine operation.

Important Safety Note: Always refer to your vehicle's specific service manual for detailed instructions and safety precautions. Working with engine coolant can be hazardous; wear appropriate personal protective equipment.

Operating Principle

The thermostat housing is an integral part of the engine's cooling system. It houses the thermostat, which regulates the flow of coolant between the engine and the radiator. When the engine is cold, the thermostat remains closed, allowing the engine to reach its optimal operating temperature quickly. Once the engine reaches the set temperature, the thermostat opens, allowing coolant to flow to the radiator for cooling. The housing provides the necessary connections for coolant hoses and ensures a sealed environment for the thermostat's operation.

Maintenance

The Dorman 902-1038 thermostat housing is designed for long-term durability. Regular maintenance of your vehicle's cooling system is crucial for the longevity of all components, including the thermostat housing.

• Coolant Checks: Regularly check coolant levels and condition. Replace coolant according to your vehicle manufacturer's recommendations.
• Hose Inspection: Periodically inspect coolant hoses connected to the housing for cracks, leaks, or signs of wear.
• Leak Detection: Be vigilant for any signs of coolant leaks around the housing or other cooling system components.
• System Flush: Perform cooling system flushes as recommended by your vehicle manufacturer to prevent corrosion and buildup.

Troubleshooting

If you experience issues with your vehicle's cooling system after installation or during normal operation, consider the following common troubleshooting points related to the thermostat housing:

• Engine Overheating:
  • Possible Cause: Thermostat stuck closed, air pocket in the cooling system, low coolant level, faulty water pump, clogged radiator.
  • Action: Check coolant level, bleed air from the system, inspect for leaks, consider professional diagnosis.
• Engine Running Cold (Slow to warm up):
  • Possible Cause: Thermostat stuck open.
  • Action: A thermostat stuck open will not allow the engine to reach optimal operating temperature, leading to reduced fuel efficiency and increased emissions. Professional diagnosis is recommended.
• Coolant Leaks:
  • Possible Cause: Improperly seated gasket, loose bolts, damaged housing, cracked hose.
  • Action: Inspect the housing and hose connections for visible leaks. Ensure bolts are tightened to specification. If the housing is damaged, it requires replacement.

For persistent issues, consult a certified automotive technician.

Specifications

Warranty and Support

For specific warranty information or technical support regarding your Dorman 902-1038 Engine Coolant Thermostat Housing, please contact Dorman Products directly. Refer to the official Dorman website or product packaging for the most current contact details and warranty terms.

Manufacturer: Dorman Products

Website: www.dormanproducts.com