Having just changed the t-stat on my '92 Exp, 4.0L, I thought I'd share a few things I learned that I didn't notice anywhere else on the forums.
See following for excellent description of removal procedures:
http://www.explorerforum.com/Singleton/web/pages/thermostat.html
As discussed there are a couple(1 in particular) bolts on the housing that are very hard to get at.
After getting the belt out of the way, the tensioner moves a little out of the way. Next, remove the top bolt that holds the tensioner assembly in place; take a hammer and punch/large screwdrive and gentlly tap the assemblly up and a little more out of the way, it will rotate at the other bolt that's behind the tensioner pully. This will give about 3/8" that will make all the difference in being able to get at that bolt(you'll know the one). Now, with a screwdriver and using head of the bolt to lever on, gentlly press the small wiring harness against the t-stat housing, This will get the harness out of the just enough so it will not be in the way. With this, the bolt came out pretty easy
When putting the bolts back in, I used a small bit of duct tape to hole the bolt in the socket; most of the tape was on the socket so once the bolt was started back in, the bolt would disengage from the socket.
A few other good tips I got from the forum article:
-Tape the sockets, extensions, wobble drives on so the don't fall off.
-Have a magnetic retriver handy when you extract the bolts
Hope this helps.
See following for excellent description of removal procedures:
http://www.explorerforum.com/Singleton/web/pages/thermostat.html
As discussed there are a couple(1 in particular) bolts on the housing that are very hard to get at.
After getting the belt out of the way, the tensioner moves a little out of the way. Next, remove the top bolt that holds the tensioner assembly in place; take a hammer and punch/large screwdrive and gentlly tap the assemblly up and a little more out of the way, it will rotate at the other bolt that's behind the tensioner pully. This will give about 3/8" that will make all the difference in being able to get at that bolt(you'll know the one). Now, with a screwdriver and using head of the bolt to lever on, gentlly press the small wiring harness against the t-stat housing, This will get the harness out of the just enough so it will not be in the way. With this, the bolt came out pretty easy
When putting the bolts back in, I used a small bit of duct tape to hole the bolt in the socket; most of the tape was on the socket so once the bolt was started back in, the bolt would disengage from the socket.
A few other good tips I got from the forum article:
-Tape the sockets, extensions, wobble drives on so the don't fall off.
-Have a magnetic retriver handy when you extract the bolts
Hope this helps.
