the thermostat housing cracking and leaking seems to be a growing problem with the V6`s lately to cars with as little as 30k to 100k. at 65k i decided to replace all my hoses, stat and upper and lower housing as preventative maintenance. the hoses went as expected, then i had the problems others have faced with the sensor not fitting in the new housing and leaking.( teflon tape has been the bandaid) you need to buy the new sensor with the housing and it fits great.
when you go for parts:
a) get a new thermostat( this is the time to replace it)
b) upper and lower thermostat housings
c) 1- o-ring for the stat, 1- o-ring for under the lower housing( looks more like a rubber band than a o-ring)
d) new temp sensor
some of the pics were my first attemp, and i just did the hoses, and today i did the housing and 1 small hose off the bottom of the water pump that i forgot to buy last time.( the hose job is not included here)
1) make sure your car is cooled down. loosen the radiator cap on top and drain the coolant. the pastic wingnut valve is on the bottom corner of radiator on passenger side.( pic1)
2) remove you cai or air box from the TB while it is draining and move it out of the way.
3) remove the connector from the frt rt side of TB by sliding the red tab forward, then pressing the exposed spot and pulling forward. remove the 4 TB bolts. i think they are 8mm but a 5/16 works fine.(pic2) unplug the TB connector on the left side by squeezing and pulling and set the TB out of harms way.(see Note),(pics3&4) remove the upper radiator hose.
Note: if you have a 05, you have 2 cooling lines that need to be removed under the TB. i bypassed that before, now would be a good time to do the bi-pass if you havent yet. its not needed. heres a link to that job http://www.allfordmustangs.com/forum...ss-review.html
4) its alot easier to just remove the fan belt and idler pulley right now. you can use a 3/8" ratchet with a 1/2" socket on the tensioner pulley on the inside to swing the tensioner and remove the belt easily.(pic5) move the belt down a little out of the way and remove the idler pulley bolt, its a 15mm bolt, and set the pulley out of harms way.(pic6)
5) remove the small angle hose from the top of the stat housing.(pic7&8) and remove the temp sensor connector.(pic9)
6) loosen the clamps on the angle hose on the frt center lower stat housing. (easy to get to with the idler pulley gone) its almost off