hunterjamison
Member
- Joined
- February 5, 2008
- Messages
- 15
- Reaction score
- 0
- City, State
- Sunny Central Oregon
- Year, Model & Trim Level
- 04 XLT SOHC 4.0L
So last week I gunned the engine to turn left onto a busy highway and was pleased at the G's. Next thing I know theres little puddles of green where I park. Opened the hood & saw pools of coolant on the manifold. While checking for leaks, took a flashlight and found what I thought was a rat's nest on top of manifold. This was just the remains of a bag put in place to absorb engine heat protecting the intake. Using a mirror and light I found the seeping leak on the rear of the lower thermostat housing. Ran it very carefully and short distance for a week, replaced it for $53 motorcraft from Oreillys plus $11 coolant. Was going to buy a t-stat at the same time since I had it all out but didn't want to pay $18 extra! When I pulled out the original t-stat it was in 2 pieces. Put it back together the same way inside the new lower housing. Bolted down & reconnected hoses, temp sensor. Added 1 GAL coolant to reservoir and started engine. BIG LEAK from ECT sensor! The port on the new housing is larger than the OE. Called FORD, sevice tech said, "Yup, see that one alot. We just put in a bigger O-ring." Luckily my neighbor was heading 12 blocks to ACE hardware and I didn't have to ride my bike in the rain, 41 deg F. Took the sensor w/ me to compare o ring sizes and purchased two for 25¢ each. Had to push it down hard, was afraid of breaking the plastic top, but was able to insert the metal retainer into the housing and the larger size O-ring kept a tight seal. Took a test drive and everything was uneventful. Got right up to temp as usual and the heater got going just as it always does, like a furnace! Still, I was worried my thermostat might be acting stupid if it is separated, so I bought a new one for $16 at Oreilly's. Murray Plus. Next day drained a gallon of coolant and while draining, torqued lower housing bolts to 89 ft-lbs. Think I #@ed up here, because one of them broke off. No need to put in a new stat now! Gotta take it all apart again anyway. Got my unreputable Easy Out kit ready and took it apart (again). Got lucky-the bolt was 1/8" above manifold! Vise Grips got it. Replaced with a cheesy different headed bolt, no OE bolt available, but got it tight enough, w/ enough washers. While apart I installed the new thermostat and gasket. Everything is operating exactly the same, temp right below half way on the gauge, the best part is NO LEAKS!
My questions are:
-Ft-lbs or In-lbs!!??
-Where do I get a replacement for the 75mm 6X1.0 8mm flange bolt I busted?
-Why did my tstat work properly when in 2 separate pieces?
-How do I repair the old housing? There has to be a way to seal the little pinholes in the glued seam on these. Has anyone seen a more durable replacement? Not plastic?
My questions are:
-Ft-lbs or In-lbs!!??
-Where do I get a replacement for the 75mm 6X1.0 8mm flange bolt I busted?
-Why did my tstat work properly when in 2 separate pieces?
-How do I repair the old housing? There has to be a way to seal the little pinholes in the glued seam on these. Has anyone seen a more durable replacement? Not plastic?