P0128 on Ford

Both the 3.0L Vulcan V6 and 4.0L Cologne V6 in the Aerostar are prone to head gasket failure, particularly after 100,000 miles. The 4.0L OHV engine is more susceptible due to its pushrod design creating uneven thermal expansion between the iron block and heads. Coolant leaks externally at the gasket surface or internally into cylinders and oil. The 3.0L develops cracks between cylinders on the gasket that allow combustion gases into the cooling system.

The plastic intake manifold on the 4.6L V8 is prone to cracking near the thermostat housing crossover, causing coolant to leak externally or internally into the engine oil. This was subject to a class action settlement.

The 2.0L EcoBoost engine in 2015-2019 Ford Edge is notorious for internal coolant leaks where antifreeze bypasses the head gasket and floods the combustion chambers. Ford's open-deck block design with scored channels between cylinders creates an inadequate sealing surface that degrades over time. Ford acknowledged this in TSB 19-2208 (later TSB 22-2229) and the prescribed fix is complete engine long block replacement costing $7,700-$10,000+. Ford never issued a recall, relying instead on TSBs and limited extended warranty coverage. The 2020+ redesigned closed-deck block resolved this issue. CarComplaints.com lists 43+ complaints for the 2017 Edge alone specifically for coolant leak into cylinder.

The 1.5L EcoBoost engine in 2017-2022 Ford Escapes suffers from a critical design defect where coolant leaks internally into the combustion cylinders. Ford engineers determined the engine block is made of porous material with an insufficient sealing surface between cylinders. The open-deck block design with scored passages between the inboard cylinders creates a weak point that cannot sustain 21 psi of coolant pressure over time. The cylinder head warps, the head gasket fails, and coolant floods the cylinders causing hydrolocking or catastrophic engine failure. Ford acknowledged this with TSBs 19-2139 and 19-2375, and extended warranty coverage to 7 years/84,000 miles for short block replacement. A class action lawsuit (consolidated) covers 2013-2019 Escape, 2013-2019 Fusion, and other EcoBoost-equipped vehicles.

The 2.0L EcoBoost in 2015-2019 Ford Escape suffers from the same fundamental open-deck block design defect as the 1.5L variant. Coolant leaks internally through the cylinder head/block interface into the combustion chambers. Ford issued TSB 19-2208 in 2019 (later updated to TSB 22-2229 in 2022) acknowledging the problem. The fix per TSB requires complete long block engine replacement costing $7,000-$10,000 at dealers. Ford redesigned the block in 2019 with a closed-deck layout, so 2020+ 2.0L engines are not affected by this specific issue. Class action lawsuits are pending covering 2013-2019 EcoBoost vehicles.

The 2.0L Split Port Induction engine is prone to head gasket failure, often caused by overheating from a failed cooling fan or thermostat. The composite gasket deteriorates and allows coolant into cylinders.

The 6.0L Powerstroke diesel (2003-2005 Excursion) is notorious for TTY head bolt stretching under boost pressure, causing head gasket failure. This is the same engine used in Super Duty trucks and is one of the most problematic diesel engines Ford produced.

The 3.5L V6 engine (both naturally aspirated and EcoBoost versions) features an internal water pump located under the engine front cover. When this pump fails, it can leak coolant internally into the engine crankcase, contaminating the oil and potentially causing catastrophic engine damage if not caught immediately.

The plastic thermostat housing on the 1.6L engine develops cracks and leaks coolant. The plastic becomes brittle from heat cycling over time. This can lead to overheating if coolant loss goes unnoticed.

The 1.5L EcoBoost in 2014-2019 Ford Fusion is affected by the same open-deck cylinder block design defect as the Escape. Coolant leaks internally from the block passages into the combustion chambers due to insufficient sealing surface and porous block material that cannot maintain coolant pressure over time. Ford extended warranty coverage to 7 years/84,000 miles for short block replacement per TSB 19-2139 and TSB 19-2375. A consolidated class action lawsuit covers 2013-2019 Fusion and Escape with 1.5L, 1.6L, and 2.0L EcoBoost engines. Some owners have experienced engine failure with no warning - no check engine light before coolant hydrolocked the cylinder.

The 2.3L EcoBoost engine in 2015-2019 Mustangs is prone to head gasket failure, particularly in vehicles that experience repeated heat cycles or are driven hard. Block distortion over multiple thermal cycles creates gaps between the engine block and cylinder head that the gasket cannot seal, allowing coolant to enter the cylinders when the engine is cold. Ford redesigned the engine for 2020+ models.

Early 2.3L EcoBoost Mustangs can experience coolant intrusion into the combustion chamber through cracked cylinder head or head gasket failure. This can cause white smoke from exhaust, coolant loss, and potential engine damage if not addressed.

The 4.0L SOHC V6 used in 2005-2010 Mustangs commonly develops coolant leaks from the composite thermostat housing and related seals. The plastic housing can warp or crack with age and heat cycling, causing external coolant seepage and sometimes overheating if the leak worsens. This is a well-known issue across Ford applications using the same 4.0L engine and is frequently documented in owner forums and repair databases.

The 2.3L Duratec-equipped Ranger is known for coolant leaks from the thermostat housing assembly and related plastic cooling components. Owners report seepage or sudden cracking near the housing, leading to coolant smell, low coolant level, and occasional overheating if ignored. The problem is common enough in owner forums and repair databases to be considered a known age-related weakness on these trucks.

The 3.0L Vulcan V6 engine is susceptible to head gasket failure, often presenting as coolant mixing with oil or external coolant leaks. The composite head gaskets deteriorate over time, especially with overheating events.

The naturally aspirated 3.8L Essex V6 Thunderbird shares the same head gasket vulnerability as the Windstar and Mustang. The composite gaskets fail between coolant passages and cylinders.

The 1.6L EcoBoost engine in 2014-2018 Ford Transit Connect has documented issues with coolant loss, overheating, and in severe cases engine fires. Ford issued Recall 14S11 (NHTSA 14V309) for 2013-2014 models covering coolant leakage from the cylinder head that could contact hot engine components and cause fire. The 1.6L EcoBoost was also susceptible to head gasket failure and internal coolant leaks similar to the 1.5L and 2.0L EcoBoost engines in other Ford models. The engine was discontinued and replaced by the 2.0L EcoBoost in later Transit Connect models. The FordTransitConnectForum documents numerous cases of premature engine failure on 1.6L-equipped vans used in commercial service.

The 3.8L Essex V6 in the Windstar is notorious for head gasket failure, often caused by the aluminum heads warping from overheating. The composite head gaskets deteriorate and allow coolant into combustion chambers.