I watch your videos all of the time and I need some help. I have a 2005 Ford freestyle. the battery froze and swelled up when it was below zero outside and it sat for most of the winter before I just now finally put a new battery in it. she starts right up BUT the instrument cluster isn't working and it chugs and I also smell something burning, like rubber or electrical. what would be causing that it does have a coolant leak coming from the top of the thermostat housing unit as well.
it chugs
What do you mean by this? Is the engine struggling to run?
How often did you drive the van before the battery froze? I've never heard of lead-acid batteries freezing, at least not in the lower 48 states. Lead-acid batteries don't freeze until -80 degrees Fahrenheit for a fully charged battery. Seriously discharged batteries can freeze at much warmer temperatures. You should have charged the battery on a battery charger/maintainer if you don't drive often and are getting ready to experience frigid temperatures.
This is key to why your battery froze. A discharged battery has a lot of water and little sulfuric acid. A fully charged battery contains a high volume of sulfuric acid and little water. More water decreases the freezing point of the electrolyte, as you unfortunately found out. Lead dioxide is the positive plate, elemental lead is the negative, and there's the aforementioned electrolyte. A bit of sulfuric acid and lead dioxide is converted into lead sulfate and water when you start the car, discharging it slightly. The car also slowly discharges the battery when it's off to maintain your clock, etc. The battery is recharged via the alternator and converts the lead sulfate back to lead dioxide, elemental lead and sulfuric acid.
it does have a coolant leak coming from the top of the thermostat housing unit as well.
Replace the thermostat housing and thermostat with a new Motorcraft one.
