Coolant Leak w/ Broken Lower Thermostat Housing Screws

[Ricklife]

Hi guys. So im going to sell my explorer so i look up the code the CE light gives and its thermostat. So i replace thermostat and notice coolant puddled in valley behind housing so i decide to replace housing. I knew i had a small coolant leak and thought good ill fix that too. I take bolts out, get new plastic housing, etc. I go to put bolts back in and realized 2 of the 3 were broken off in the manifold screw holes. 2 days of extraction kits and a torch later they will not budge. So i said screw it and cut them off flush, put the one screw back in and used the plastic to metal jb weld on the bottom hole where housing meets manifold. I also put the black plug in the 2nd open hole beside my sensor as i wasnt sure what to do with it. Next day, awesome, no leaks. Got on highway day 2 after repair, gunned it to merge and see a puff of white smoke out tailpipe and the smell of antifreeze. Immediately pulled over and looks like that plug was missing. I ended up trying to test it to see where leak was coming from and it seems to be from the bottom of the sensor hole and the other not used hole that had the plug in it. But its pouring out almost and i cant exactly see where from. So 1) is that damn 2nd hole supposed to be plugged or not? Theres coolant right up to the top of it now so i cant see why it wouldnt need to be plugged. Other vids i watch look like they have nothing in that hole 2) that clip seems to want to slip out its groove a lil and the sensor is def not feeling tight in there even with the clip in it. 3) Could it be coming from the sensor hole itself? 4) Also reading that some weld on the back of lower housing could be leaking. A weld on the plastic? I dont understand. I know those 2 screws not holding down now could aide in my problem but guys, they are not budging. They might as well be part of the manifold now. Thats how joined they are to that hole now. Please help. Im hoping i didnt blow gasket. I checked dipstick and oil cap and no milky froth anywhere. Just the one puff of white smoke from tailpipe when i gunned it. Uggh. TIA

 

[Mr. Alligator]

These thermostat housings, especially the plastic ones, are difficult even with the mounting hardware intact. Sounds like you need to start over, going back to address the two broken bolts in the manifold. You might/probably have to remove the manifold to remove the broken bolts, and maybe even replace the lower manifold. JB Weld, or any type of metal epoxy, is not adequate. The plastic “weld” on the thermostat housing parts is part of the manufacturing process. Salvage might be a good source for the replacement manifold, if necessary.

Good luck.