Ford - Explorer :: Coolant Not Returning To Radiator From Expansion Tank


Jun 24, 2015

Last week during a hot/long day on the road, my engine temp gauge started fluctuating between 1/2 and almost 7/8 on the gauge. The weird thing was that it was fairly stable most of the time, but every 10 minutes or so, it would heat up, and spend bout 15 seconds at the high mark before dropping down again. It didn't seem to be related to rpm, A/C operation, or driving intensity. When I got home, and let it cool down, I checked the coolant level. I couldn't see any coolant in the radiator, but the expansion tank was nearly full. I guess the low coolant level can explain the symptoms above, but I can't figure out what is happening to the coolant.

I took the car to a mechanic and had a pressure test, which didn't show any leakage. I had a new thermostat and radiator cap installed. They flushed the system, and tested the hose between the expansion tank and radiator. After driving the car home, the coolant in the radiator had already dropped to the point where I couldn't see it, and the expansion tank was 3/4 full. Now, I am planning to keep track of the levels of both reservoirs (and refilling the radiator of course) to see if the fluid is leaking, or if it is just not returning from the expansion tank. Hopefully this bit of knowledge should locate the problem.

The successful pressure test leads me to believe that it isn't leaking externally. However, I'm wondering if there is a small enough leak that wouldn't be detected by the pressure test, but is significant enough that it would allow air in when the engine cools instead of pulling the fluid back from the expansion tank.

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Friday, my wife returned from work (30 mi., interstate drive). After being parked for 45 mins, went out to find fluid puddle at very front of car. Expansion tank was empty. Looked in radiator, and it was about one inch to inch and a half below bottom of rad cap...about level with rad seam, where the black plastic top is attached to metal. I topped off the rad. this time, along with filling expan. tank to cold-fill line. Turn car on, and after warming up coolant starting coming out from what appeared to be the seam at the top of the rad., where the black plastic portion meets the metal part of the rad.

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