So, just had some services completed by FordTechMakuloco this past week. Timing chain & associated components, rear differential fluid exchange, cooling system flush, spark plugs, and valve walnut blasting.
For the flush I had a few components on hand already. One being the OEM thermostat. When I checked on maintenance progression a day before pickup I asked if they saw the thermostat I had in the back where the plugs were. Was informed that the OEM thermostat is one of the better makes that doesn’t need to be replaced like others.
Typically, during a flush, or a water pump replacement I’ll do the thermostat & gasket, and all hoses for a few reasons… one, your already there with the system open; why not? Two, that stuff isn’t as expensive as the damage it could potentially cause.
Moral of the story is it didn’t get changed because it’s supposed to be fair superior. Obviously, there comes a point in time when it absolutely has to be done. Maybe, just maybe this might help you make a decision.
How many 3.5 liter owners have had an issue with their OEM thermostats? I also have an ‘04 Expedition with the 5.4 liter with approximately 304k-305k miles on it. I’ve replaced the water pump, all hoses, and thermostat once. Now, there was an incident she had with it, but she’s not able to tell me the specifics. What I do know is I found the underside of the plastic manifold where the water crossover pipe seats had a blowout at the channel where the rubber gasket seats. Since the plastic housing lost pieces of the channel the gasket couldn’t hold it’s seal. Antifreeze leaked out on top in the pocketed area of the cylinder block; under the manifold. When investigating I could never find a leak. Nothing made itself obvious. Loosing antifreeze, but no signs as to where it was coming from.
Decided to get under it. Put the truck on ramps, then antifreeze started dropping on the ground. Hmmm… I was confused. Followed the stream up as far as I could from under the backside of the engine. Got out to look under the hood. I could barely see it but, I thought something was vibrating. Got a light… low and behold, it was a pool of antifreeze just hanging out. This lead me to the water crossover pipe under the manifold.
Replaced all hoses, thermostat, water pump, and a new manifold. Oh, flushed the system out, and cleaned the crud out of the degas bottle while I was at it.
That extra info was more support to the original moral of that OEM thermostat lasting to at least 150k miles; that last thermostat was second one I installed.
Got a little long winded… just wanted to share my personal experience with Motorcraft components. I’ve found that other manufacturers aren’t necessarily better. JMO.
Good luck on your issue. Hopefully you get it resolved the least painful way possible, Sir!!!