I Have HAD IT!
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Cargo Master
Joined: Dec 2004
Posts: 3,362
Likes: 22
From: Florence, SC
I Have HAD IT!
I have HAD IT! I have done everything I know to do to seal up this blasted thermostat housing, but I am unsuccessful. This is a brand new aluminum unit and gasket I bought from CarQuest, and this is the exact same unit NAPA and the rest sells. (An OEM Motorcraft unit for a 1985-1986 costs almost ONE HUNDRED AND FIFTY DOLLARS from Ford! 
)
I cleaned and even lightly sanded both surfaces to make sure they were smooth. The thermostat has not slipped in the housing, and both screws are new and are as tight as they can get. Yet I still have an annoying little leak at the bottom. I don't have any leaks on this truck so far, and I am not about to let this one go.
What really tweaks me is that it did not leak at all the first three days after I replaced it. So, WHY IS IT LEAKING NOW?
) I cleaned and even lightly sanded both surfaces to make sure they were smooth. The thermostat has not slipped in the housing, and both screws are new and are as tight as they can get. Yet I still have an annoying little leak at the bottom. I don't have any leaks on this truck so far, and I am not about to let this one go.
What really tweaks me is that it did not leak at all the first three days after I replaced it. So, WHY IS IT LEAKING NOW?
Elder User
Joined: Apr 2009
Posts: 922
Likes: 1
From: San Diego
Did you use any sealant at all? I don't know if it will help you or your frustration, but I put on latex gloves and rub red rtv into my water pump, and thermostat gaskets before bolting them up. I don't use a lot, just enough to smear on both sides of the gasket and make them tacky and appear red. The goal I had was to not have any squeeze out, it seems to work like a charm. (of course this is with the stock water neck.)
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Cargo Master
Joined: Dec 2004
Posts: 3,362
Likes: 22
From: Florence, SC
Yes, I used Indian Head shellac the first time and it leaked real bad, but I had trouble getting the housing on and had to keep moving it around. This time I used a gasket sealant coated on both sides of a new gasket which seemed to work great until three days later. I have a very small leak that shows up overnight on the left hand corner of the housing. 
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Cargo Master
Joined: Dec 2004
Posts: 3,362
Likes: 22
From: Florence, SC
Is it better to put the gasket on in intake manifold, and then bolt up the housing?
Or is it better to put the gasket on the housing itself, and then bolt it to the intake manifold as an assembly?
Or is it better to put the gasket on the housing itself, and then bolt it to the intake manifold as an assembly?
Methanoholic
Joined: Mar 2009
Posts: 6,442
Likes: 8
From: Maine (NorCal Native)
Them cheap cast aluminum aftermarket housings are JUNK!
They are typically not flat!
Smooth is not whats needed, Use a piece of emery paper on a plate of glass ... This ensures it's flat.
If all else fails use Permatex High Tack Gasket Sealant ... You will hate this stuff (and likely me for suggesting it) if you ever have to remove it, Stuff is like TAR and is a nightmare to remove, however it'll seal even the toughest of leaks!
If you have a pretty Aluminum manifold ... I HIGHLY suggest you not get any High Tack on it!
-Enjoy
fh : )_~
They are typically not flat!
Smooth is not whats needed, Use a piece of emery paper on a plate of glass ... This ensures it's flat.
If all else fails use Permatex High Tack Gasket Sealant ... You will hate this stuff (and likely me for suggesting it) if you ever have to remove it, Stuff is like TAR and is a nightmare to remove, however it'll seal even the toughest of leaks!
If you have a pretty Aluminum manifold ... I HIGHLY suggest you not get any High Tack on it!
-Enjoy
fh : )_~
Cargo Master
Joined: Mar 2007
Posts: 2,935
Likes: 34
From: Arcadia, Fla
I had same problems before, finaly just used that "import grey" rtv without a gasket, no more leaks. Some gasket material leak depending on how it's made(multy layered) and weep through it.
