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Posted: 7/20/2008 5:56:52 PM EDT
Hey guys, I've been trying to replace the thermostat and outlet housing on my 95 F-150 and after I got the new one on it leaked as soon as I filled up the radiator. Any ideas on what it could be?

I'm kinda wondering if the thermosatat slipped out of alignment and got pinched between the outlet housing and the engine block's mating surface. Is that possible?

Thanks, Monte.
Link Posted: 7/20/2008 6:13:55 PM EDT
Link Posted: 7/20/2008 6:16:38 PM EDT
[Last Edit: 7/20/2008 6:20:48 PM EDT by ampn]

Originally Posted By MonkTx:
Hey guys, I've been trying to replace the thermostat and outlet housing on my 95 F-150 and after I got the new one on it leaked as soon as I filled up the radiator. Any ideas on what it could be?

I'm kinda wondering if the thermosatat slipped out of alignment and got pinched between the outlet housing and the engine block's mating surface. Is that possible?
Thanks, Monte.


Yes.

Is it a 5.0/5.8? If so, there is a recessed area in the water outlet that the thermostat seats into. I would glue that sucker on with the gasket and then install it. Be careful because if it isn't in there all the way the housing may crack when tightened.
Link Posted: 7/20/2008 7:21:38 PM EDT

Originally Posted By ampn:

Originally Posted By MonkTx:
Hey guys, I've been trying to replace the thermostat and outlet housing on my 95 F-150 and after I got the new one on it leaked as soon as I filled up the radiator. Any ideas on what it could be?

I'm kinda wondering if the thermosatat slipped out of alignment and got pinched between the outlet housing and the engine block's mating surface. Is that possible?
Thanks, Monte.


Yes.

Is it a 5.0/5.8? If so, there is a recessed area in the water outlet that the thermostat seats into. I would glue that sucker on with the gasket and then install it. Be careful because if it isn't in there all the way the housing may crack when tightened.


It's a 4.9. I guess I'll pull it off and try it your way tomorrow.
Link Posted: 7/21/2008 12:14:57 AM EDT
Some thermostat housings are made of aluminum, if the system wasn't maintained with antifreeze, the water, and iron metals will corrode the housing. Sometimes developing pinhole leaks.

Here is a good pointer, before installing the new thermostat, drill a small hole 3/32s to 1/8th. in the mounting flange. This will allow you to fill system and not have to burp it.

It also helps the thermostat work more efficiently
Link Posted: 7/21/2008 12:24:21 AM EDT
Gasketing. Did it have a gasket or is it a newer o-ringed model? Either way, it needs a new one.

I replaced the T-stat in my bro's 2k Dakota, paper gasket. When you pull the cover, both gasketing surfaces need to be cleaned flush. And a good sealant helps bond the gasket to keep it in place.

With O-ringed T-stats, the seat needs to be PERFECT. Any nicks and sealing will be difficult. Clean, perfectly clean and smooth.
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