94 explorer thermostat removal tips

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Jan 23, 2005 | 12:17 PM

hu5ker555

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94 explorer thermostat removal tips

I just replaced a thermostat on my 94 X. Thought I'd explain how I got the three bolts off - it wasn't easy.

I'll explain each bolt as you look towards the thermostat housing.

The upper left bolt was the toughest. All I could get on the bolt was a 10 mm box wrench. Could only get 1/8 of a turn each time and needed to really tug on the a/c line that got in the way with each turn. Once it was busted loose, I could barely get two fingers in there to twist it out.

The lower right bolt was the easiest. I used a 10mm socket with about a two inch extension. Pretty straightforward.

The lower left bolt was tricky. I took the 10mm socket and two inch extension and clamped a pair of vicegrips about midway down the extension. This allowed me to lower the socket down onto the bolt and slowly back it out.

I hope this helps someone down the line...

Jan 23, 2005 | 01:04 PM

JerrySimm

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From: Pauline, South Carolina

Unless the '94 4.0L is way different from the '92, an easier way is to raise the belt tensioner (seem's like it's a 5/8 six point socket) and lock it (by pressing in on the flat spring in the back and gently letting off the tensioner). Then remove the two bolts that hold the belt tensioner on and remove the tensioner. Then you can get to all 3 thermostat bolts with a ¼" drive 10mm socket, 2" extension, and a ratchet. To me that way is easier. Out & Back in takes 20 to 30 minutes.

Jan 23, 2005 | 01:27 PM

marragtop

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From: Baltimore

Jerrysimm is correct. If you take the belt off the tensioner automatically springs out of the way. Also, it's easier if you have a thin wall 10mm socket.

Dec 12, 2005 | 11:55 PM

ChampCar

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Quote:

Originally Posted by JerrySimm

Found this in my search since I will be doing the Thermostat tomorrow.

>>lock it (by pressing in on the flat spring in the back and gently letting off the tensioner).

I'm abit unclear, so I'm hoping someone can answer. Am I to understand that you can lock the tensioner in the loose position by doing this? Is it obvious how to do it? Will you need another person to help doing this? I've replaced the serpentine belt and have loosened the tensioner, but I've never looked behind the tensioner when I was doing it (too busy trying to loosen the tensioner and put the belt in place to look behind

) to see what is back there.

Also, how do you place the tension back?

Any other tips for an easy T-stat change?

TIA

Last edited by ChampCar; Dec 13, 2005 at 12:00 AM.

Dec 13, 2005 | 05:00 AM

marragtop

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From: Baltimore

Make sure you get an new o-ring gasket for the t-stat. You may have to ask for it seperately.

Dec 13, 2005 | 05:58 PM

JerrySimm

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From: Pauline, South Carolina

Yes, you can lock it open. I usually do it myself, I don't want someone else dropping the tensioner on my hand. You must use the correct size socket, and a 2 foot or longer pull handle makes it much easier. When you raise the tensioner up with one hand, there is a flat piece of spring steel near the base of the hub on the back side of the idler pulley. You must push this towards the center of the pivot point for the tensioner with the other hand while moving the tensioner up. There is a slot that it will click into. You must hold it in the slot while letting off on the pull handle to slowly lower the tensioner. To release it later, simply raise the tensioner with the pull handle and the spring lock will pop out of the slot, and then you can lower the tensioner. If you ever see one of these from the back when it's off the engine it's obvious how it works, from the front not so much. Once you do it, you'll see, but it may take a couple of trys the first time.

hope this helps................

Dec 14, 2005 | 01:14 AM

ChampCar

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Hi Jerry

Thanks for the additional info. Your description was right on!!!

I was able to do it on the first try.

Quote:

If you ever see one of these from the back when it's off the engine it's obvious how it works, from the front not so much.

You are so right about that. I've taken some pictures to help. Here is the link:

http://community.webshots.com/album/523048973xJjFFm

If anyone is planning to do a T. Stat change on 4.0L OHV, removing the tensioner makes it SO EASY! It's a must. The last time I did it, I did not remove it and what a painful experience it was since it restricted access to the one bolt.

I've taken a lot of pictures of me doing it tonight, so I will write it up and post it on the forum for future reference. Since the holidays are coming, it will take longer than usual.

Thanks again to the forum and especially you Jerry.