can't seem to thread sensor into lower thermostat housing

[matt351]

Some reason I can't get the passenger side most sensor to thread into the thermostat housing. Am I missing something here guys?

 

[matt351]

I can't seem to remove the damn thing either. It's like it's loosely stuck in there

 

[2000StreetRod]

insert slipping?

The stock 2nd generation lower thermostat housing is a poor design. The "plastic" housing contains brass threaded inserts for the two sensors. If you're not very careful when removing/installing a sensor the insert will slip and probably leak coolant. I epoxied the insert to the housing to keep it from slipping.

However, after a few years the epoxy came loose due to changes in temperature and the expansion/contraction of the housing.

In later generations the screw in sensors are replaced with clip in sensors but the "plastic" housing will still eventually crack and leak.

If you have to replace your stock housing you should consider upgrading to the later design.

I chose to upgrade to an aftermarket, rather expensive aluminum housing.

 

[swshawaii]

Here's the other upgrade.

http://www.explorerforum.com/forums/showthread.php?t=239493

 

[matt351]

We'll I had to order a new thermostat housing... The insert for one of the sensors pulled itself out... Oh joy... What a craptastic design!