When you click on links to various merchants on this site and make a purchase, this can result in this site earning a commission. Affiliate programs and affiliations include, but are not limited to, the eBay Partner Network.
I have a 1984 Ford F150 with a 4.9 L 300 I6, 2dr, Styleside, 2WD.
Truck restored bottom the top all parts are new.
My thermostat housing cracked. As you know, they are difficult to find. The ones I’ve been looking at, none of them mention diameter of the heater inlet tube to thermostat housing or the thermostat housing to block.
Dorman DL 902–1002 fits a 91 and the inlet tube to thermostat housing is large.
Parts Catalog has one for an 85, and the heater inlet tube to thermostat housing is large.
Dorman DL902-1025 fits an 84’ but the heater inlet tube to thermostat housing looks small.
when I say large and small I’m comparing it to my heater inlet tube to thermostat housing fitting, which by the way is 1”.
I just ordered all three.
Im hoping that the either the 1002 or 1022 heater inlet tube to housing will work.
As for the 1025- is it possible to have a machine shop bore and tap the heater inlet tube hole on the thermostat housing to fit my heater inlet tube fitting?
I know the junkyard is a final option but here in California you don’t see too many 80s or even low 90 trucks in junkyards.
and don’t get me started on the heater inlet tube fittings. You can’t find those anywhere except maybe a junkyard.
have any of you experienced this? What have you done to make it work?
That is simply pipe threads correct? You should be able to go to the hardware store or a large plumbing supply and get a hex bushing adapter if the replacement has threads that are too large. It will look like this.
I dont know where the break down years between small & large port is but the motor in my 81 F100, not a 81 motor but later, had the large port.
The first one I got from AZ was the small so returned it and someone on the form said the O'Rielly had the right size and sure enough they did.
This was over 6 years ago and dont know who made the part or the part number.
The 4.9 / 300 stat housing breaking is a normal thing. I was cleaning the gasket off mine when the ear broke off
The clue should have been the RTV on it that it was broken before I got my hands on it.
Keep us posted
Dave ----
Like was posted by Dave I am not sure of the year changes, but when mine on my 81 broke I got a replacement that was made by the company 4 Seasons. While it is China made, like im sure they all are, it was REALLY well made, and cast iron instead of the pot metal the old one was. Not sure that helps you any, just figure I would bring that up.
There are a few out there, I got one from Dorman. 902-1002, for 1990-1996 trucks. It’s aluminum. Ports a little larger but the thermostat fits perfect and the heater inlet tube I found fits perfect. Got lucky. Just have to paint the housing.
All these little things. Killing me. Makes me wanna sell this thing as quick as I can before another part breaks down that I can’t get. lol
Oh! I passed smog and I got it registered.
I think I might soon be ready to attend my first cars and coffee… geez lol
Good to hear you got the right part and passed smog.
I am guessing you have the housing in place if you did smog?
If not when you go to install it drill a 1/8" hole in the washer part of the stat and place it at the top.
This will let air pass but not do anything to how it works.
BE CAREFUL that the stat does not slip down out of the slot because when you tighten the housing will crack again.
Dave ----
the old one was in place. It was made pot metal. I saw the hairline crack near bolt hole. I must have tightened to much when I installed it awhile back. I saw the crack while checking continuity of temp sensor. I read about the hole in the top. They suggested a 1/16th., I’ll enlarge it. I still have everything apart. I put 4 little dots of superglue around the edge of the temp stat to hold it in place. Then the gasket.
1/16 I guess would work too I have always used 1/8 as the smaller 1/16 bits tend to break.
I also have a lot of 1/8 for body work so that is my go to size but if you feel the 1/16 works for you go for it.
It just has to let air pass the stat so you dont have to "burp it" much.
I got to refill my 5.9 Dodge cooling system today before the storm comes after a water pump change a few days ago, no stat change, and wonder how bad the burping will be
Dave ----
It did not go well pump leaked from the seal and so does the replacement, both same brand so think of going with a different brand?
Right now I hate just looking at the truck as this BS should never happened.
Dave ----
I wanted to pressure test the system to see just where it might be coming from but my old school Stant pump would not fit the truck last night
So this afternoon I went to HF, yes I had a bag over my head Karl, and picked up adapter kit that fits my pump but my hart is just not into looking at it at this time.
Maybe after dinner I will head out and see? They are talking of a good ice storm hitting us Saturday afternoon, Sunday and maybe Monday?
So as long as we have power I can go out and mess with it as I dont plan on going anywhere and if I have to the parts store is a 1/4 mile so could walk there and back.
Dave ----
Rezvani's Latest Post-Apocalytic Monster Is a Ford F-150 Raptor Underneath
Slideshow: Called the Fortress, the 850-horsepower pickup combines Raptor underpinnings with military-inspired features, survival equipment, and a starting price of $285,000.
