Dorman 902-1996 Engine Coolant Thermostat Housing Assembly

Dorman 902-1996 Thermostat Housing Assembly

Dorman 902-1996 is an engine coolant thermostat housing assembly built with an aluminum housing to replace weak plastic OE designs that can warp and fail over time. It is a direct-fit cooling system repair part for select Ford and Mercury applications, including Explorer, Ranger, Explorer Sport Trac, and Mountaineer models with a thread-in style ECT sensor.

Key Features

• Aluminum thermostat housing for improved resistance to heat-related warping
• Includes gasket or seal with an O-ring style seal design
• Three mounting holes and three outlet ports for the specified cooling system layout
• Package contents include the thermostat housing, sensor, clamps, and hose
• Thermostat opening temperature: 120 degrees
• Direct replacement for OE part number F77Z8A586AE

Detailed Description

This Dorman OE FIX thermostat housing assembly is engineered for vehicles that use a metal housing with a thread-in style ECT sensor. The aluminum construction helps address a common failure point in original plastic housings by reducing the chance of warping, cracking, and coolant seepage. For buyers searching for a thermostat housing assembly for 1997-2001 Ford Explorer, 2001 Ford Ranger, or 1998-2001 Mercury Mountaineer, Dorman 902-1996 provides a service replacement built around the original cooling system layout.

This part cross-references OE number F77Z8A586AE for the same application.

Vehicle Fitment

• Fits 1997-2001 Ford Explorer, N/A, Metal Housing; w/Thread-In Style ECT Sensor
• Fits 2001 Ford Explorer Sport, N/A, Metal Housing; w/Thread-In Style ECT Sensor; To 7/23/00
• Fits 2001 Ford Explorer Sport Trac, N/A, Metal Housing; w/Thread-In Style ECT Sensor; To 7/23/00
• Fits 2001 Ford Ranger, N/A, Metal Housing; w/Thread-In Style ECT Sensor
• Fits 1998-2001 Mercury Mountaineer, N/A, Metal Housing; w/Thread-In Style ECT Sensor

Common Repair Uses

• Coolant leaks from a cracked or warped thermostat housing
• Overheating caused by coolant loss at the housing connection
• Failed temperature sensor sealing at the housing interface
• Repeated replacement of plastic OE thermostat housings
• Cooling system service on Ford Explorer, Ranger, or Mercury Mountaineer models

Installation Notes and Tips

Verify the vehicle uses a metal housing with a thread-in style ECT sensor before installation. Inspect the mating surfaces, hose condition, and sensor threads during service, and replace any worn seals or damaged hoses as needed. Confirm the thermostat opening temperature and port layout match the original configuration before final assembly.

Quality Assurance

Dorman OE FIX parts are built as service replacements that address known OE failure points with updated materials and construction. This housing uses aluminum instead of plastic to help reduce future heat-related distortion in the cooling system.