[jayhawkofku]

Okay, I just installed my brand new thermostat housing unit. The old one had a slight crack and so it needed to be replaced. Started it up and noticed it's leaking from where the temp. unit inserts into the housing.

I took it out, inserted it into the old, cracked housing and its a tight, snug fit. When i insert it into the brand new housing, its super loose!

Any suggestions or ideas as to how to cure this? It doesnt make sense -- the old housing makes a tight, snug fit (w/o clip) and the new one doesn't even make a remotely tight, snug fit - Even WITH the clip in!

[nigel]

Us teflon tape or replace it with another one. Take the old one with you to compare it with.

[jayhawkofku]

Teflon tape is not going to solve the leaking. .

I just google'd it and on another Mustang website, I found a thread concerning this issue. Turns out, 05-06 Mustangs suffer from the thermostat housing going out a lot! The upper and lower housings like to crack.

Turns out, there's a small o-ring, costs 10 cents that needs to be replaced and stupid Ford didnt give it to me. So to get that o-ring, i have to pay 40.00 for a brand new thermostat sending unit, they wont separate them.

Thanks for the help though, sucks another Mustang thread helped me out first.

[ITLRUN]

Yeah, bring the old housing and temp unit with you, and let the parts store match it up for you, Mike. SCT Tuner.

[05horse]

yea i blew my t stat houseing


dont loose or break that clip its 7.50


my new houseing was a hair loose too at the sensor and i did use teflon tape.
thick ring around and its fine

and the o ring at the bottom is important as well as the 0 ring at the top



im in the prosess of getting one made out of aluminum

i got it built its a rectangle just not 100% at the bottom yet.

[jayhawkofku]

Wait a minute.

You said the o-ring at the top is as important as the o-ring at the bottom.

When I removed the sensor, there was only an o-ring at the bottom of the sensor, there was no o-ring at the top.

Do you have a picture of the sensor with Both o-rings?

[05horse]

Originally Posted by jayhawkofku

Wait a minute.

You said the o-ring at the top is as important as the o-ring at the bottom.

When I removed the sensor, there was only an o-ring at the bottom of the sensor, there was no o-ring at the top.

Do you have a picture of the sensor with Both o-rings?

theres one that seats in in the bottom, then one that is inside the hosde clamp/very top.

[jayhawkofku]

So there's also an o-ring where the clip goes into place? I was thinking of putting an o-ring there but thought maybe the clip wouldn't be able to properly hold it into place?

Any pictures by chance?

[05horse]

theres an o ring on the temp sensor if thats what ur asking. where exactly is your leak at?

where the thermostatr unit goes in right?


just roll teflon tape around i 6 times stick in and re clip. it sealed mine up

[jayhawkofku]

My leak is where the thermostat sensor unit goes into the thermostat housing.

As previously stated, on the original housing, it's a tight n snug fit without the clip in. On the new reproduced housing I purchased from Ford, its extremely loose even when clipped in.

I know there's an o-ring at the bottom of the sensor, but you mentioned one at the top. That's the one I was curious as to where it is because when I removed my sensor, there was only the lower o-ring on it.

Thanks!

[jayhawkofku]

Oh and as far as using teflon tape, I wrapped that sensor so much that i could bare put it into the housing. Re-clipped it. Started the car. Didn't take but 10 seconds for it to start leaking again.

[05horse]

Originally Posted by jayhawkofku

Oh and as far as using teflon tape, I wrapped that sensor so much that i could bare put it into the housing. Re-clipped it. Started the car. Didn't take but 10 seconds for it to start leaking again.

the sensor only has 1 o ring

mine was loose too.


if u teflon tape it and JAM it in there your ripping tape just make it snug but us houdlent have to apply much force.


then clip in place.


i blew mine way away from home and ihad to be crafty... the new parts dot seal like the old ones did

[amustangrocks]

thats nice to know. i`m getting ready to replace mine as preventative maintenance along with hoses. you might want to try the yellow gasket and weatherstrip adhesive. i use that doing water pumps. let it dry good, it wont leak. just an idea

[05horse]

Originally Posted by amustangrocks

thats nice to know. i`m getting ready to replace mine as preventative maintenance along with hoses. you might want to try the yellow gasket and weatherstrip adhesive. i use that doing water pumps. let it dry good, it wont leak. just an idea

good idea but no where to put it. and it could clog the sensor.


if u jsut experiment with tape ull get it stopped.


i put my tape around the bottom right over the o ring

[jayhawkofku]

I put the teflon tape around practically the whole sensor and it finally decided to stop leaking. For whatever reason, I'm having issues with it idling now...go figure.

But i'm calling Ford tomorrow and finding out the real solution. Teflon tape definitely works, but I can't imagine that's what they'll tell me in terms of solving this issue. There's gotta be a correct fix. I can't imagine Ford would make such a sh***y part!

Thanks for your help guys -- I appreciate it