water outlet question

[mandypowers]

My husband replaced the water outlet housing in my 2005 explorer. The replacement came with two holes, one for the sensor and one with a plug. He left the plug in the hole it was in, and put the sensor in the other. This was apparently wrong, because while I was driving it yesterday the plug popped out and I had coolant and smoke every where. So he switched them around. The plug doesn't seem as though it is really tight though, and now I am afraid to drive it. Can anyone steer me in the right direction? We got the replacement part at AutoZone.

 

[Number4]

There is a metal tension clip that fits into slots that holds the cap/plug in place. As I recall. Sounds like the clip isn't installed.

 

[Number4]

Should be able to see the clip in two of these pics.


http://www.napaonline.com/Catalog/C...-Thermostat-Housing/_/R-NDP7357814_0434625523

 

[mandypowers]

It only came with one clip, which we used on the sensor. Should there also be one on the plug?

 

[Number4]

First item to note. The unit you bought is most likely a Dorman product (in other words, it's the same thing you'll get every where except the dealer.) from what I've seen, it states 'clip on sensor.' Or something of the like. This implies that there is more than one type. Looking at a new unit, it is only supplied with one clip, which is for the plugged port. If yours originally was the same, then you'd need to reuse the clip that came with your original unit. My factory unit has two ports, but one is actually a sealed plug. On the after market version you must use a clip on both sides. You need two clips. What happened to the original clip? I'd try to find it. Dealer may sell the clip by itself.

 

[Exproblems]

It only came with one clip, which we used on the sensor. Should there also be one on the plug?

Yes, you need to re-use the metal clip that was on the previous temp sensor or the one from the old housing. The temp sensor and port plug "both" need to be clipped into place or they can pop out like yours did. The Dorman t-stat housing only comes with one clip and one port plug even though there are 2 port holes open on the housing. I bought the Dorman t-stat housing last year.