thermostat housing outlet diameter too small!

[Thuggsy]

on a 97 EX XLT 4.0 OHV...

im trying to replace my thermostat housing but the outlet diameter of the new part is too small.

ive tried the Ford part RH119 and the Four Seasons part 84883, both are way too small for the hose.

hours of online research shows:
what i need doesnt exist (except for ebay used rusty overpriced junk parts!)

what am i missing here?!
what is the correct replacement part?

(obviously my truck is dead ATM)

 

[my98nnj]

Replace the hose, it's most likely gotten soft and opened up a bit.

 

[Thuggsy]

Replace the hose, it's most likely gotten soft and opened up a bit.

thx for the reply...

hose is new/unused.

 

[alohamonte]

hose might be new but it might be for the wrong engine or year.

 

[Thuggsy]

hose might be new but it might be for the wrong engine or year.

hose is correct for engine, model, and year.

hose is 37MM on both ends, t-stat housing is only 35MM.

actually i have 2 hoses, one from NAPA and one from Ford Motorcraft, both are the same. (37MM)

 

[Maniak]

I just went outside the used my calipers on two spare thermostat housings. One measured 34 mm and the other measured 35 mm. The one that is 35 mm still has the paint where the hose goes..

I don't have a new hose to check but from my measurements, you have the right housing.

One thing though, my housings are from a 1st Gen X, but AFAIK, the housing didn't change between the early and late 4.0 OHV motors.

~Mark

 

[Thuggsy]

I just went outside the used my calipers on two spare thermostat housings. One measured 34 mm and the other measured 35 mm. The one that is 35 mm still has the paint where the hose goes..

I don't have a new hose to check but from my measurements, you have the right housing.

One thing though, my housings are from a 1st Gen X, but AFAIK, the housing didn't change between the early and late 4.0 OHV motors.

~Mark

thx for checking

that might be where the oversite lies... it did change, or at least some of them did.

both of my rad (upper and lower) hoses are 37mm, all 4 ends.

 

[Peanut74]

If you have a Pull-A-Part nearby you might search there. The one here has quite a few Ex's in it and you could measure as you go.

 

[snoranger]

I'm assuming you got the 35mm one, there is also a 40mm one. I can only come up with the Ford base part#, not the 4 digit prefix or the suffix... Its 8594.

Go onto fordparts.com and look it up as a 91 Ranger with a 4.0l and you'll find 2 choices...35 or 40 mm.

 

[Thuggsy]

Go onto fordparts.com and look it up as a 91 Ranger with a 4.0l and you'll find 2 choices...35 or 40 mm.

checking ~ thx


EDIT: nope, not correct.

 

[Thuggsy]

 

[Thuggsy]

finally got this sorted out!

the correct Ford part # is F5TZ-8594-AA

pics...