Engine 89 GT Thermostat replacement woes

[larrym1961]

A trick my Step Dad showed me years ago. On the Ford lower thermostat housing bolt once you get it out, take a hack saw and cut a slot into the head of the bolt, enough of a slot for a flathead screwdriver to fit into. Works like a charm to screw that lower bolt in and out again.

 

[Wayne Waldrep]

I guess I've just never paid it much attention but I don't seem to have trouble with the lower bolt. And I have giant hands that fit nowhere!! Maybe long fingers help but I've always threaded it in with two fingers then tightened with a wrench. Here's a pic. The bolt is wide open to me. Or either I'm missing something. Now is it as easy as taking the battery cable off? No. But it's not on my list of difficult bolts. One other thing I am fanatical about is cleaning bolts and threads. I never reuse a fastener without cleaning the threads on a wire wheel. I also chase the threads in the bolt hole. It's just a habit I got into years ago and it makes things go back together much better.

 

[Wayne Waldrep]

Here's a vid for you. I've never had to bend a wrench or pull the distributor up but it worked for him and you could adapt it however you need for yours. Hope it helps.

View: https://www.youtube.com/watch?reload=9&v=oM9VzBFyK2U

 

[gearhead77]

Here's a vid for you. I've never had to bend a wrench or pull the distributor up but it worked for him and you could adapt it however you need for yours. Hope it helps.

View: https://www.youtube.com/watch?reload=9&v=oM9VzBFyK2U

I appreciate your input, but this distributor doesn't have a TFI module that blocks a great deal of access to that area. The flex sockets solved a lot of the access issue though.

 

[Wayne Waldrep]

I appreciate your input, but this distributor doesn't have a TFI module that blocks a great deal of access to that area. The flex sockets solved a lot of the access issue though.

Yeah I just used the pic to show the bolt. My cars an '88 with the TFI. A regular wrench has always worked fine for me.

 

[gearhead77]

Yeah I just used the pic to show the bolt. My cars an '88 with the TFI. A regular wrench has always worked fine for me.

Lol, good for you! This is the first car I’ve ever really worked on besides basic maintenance, definitely a learning curve. Well, I have it all put back together for the third time. Hopefully it doesn’t leak. I’m not going to touch it until Sunday am or Sunday afternoon.

 

[Wayne Waldrep]

Good deal. Hope it's good to go now.

 

[gearhead77]

FINALLY! Success! No leaks, runs normal!

I think the culprit was the thermostat, I think it kept sliding down when I reinstalled housing. For others benefit:

1/4 flex socket set was a great idea.
Goo-gone works well for removing old gasket residue
Wiped surfaces with isopropyl alcohol after brake cleaner (91%)

Used Motorcraft gasket and Motorcraft thermostat. I tried the “twist and lock” I saw on YouTube video that only applies when using a Motorcraft thermostat , it didn’t work for me.
Applied Permatex water outlet dressing to both sides of gasket (thin coat) Placed on water outlet.
Applied thin coat to thermostat housing and placed thermostat in. Secured with rubber bands. Burp hole at 12 o’clock position.

Let it all set for 20-30 minutes
Cut head off old bolt and threaded into top hole.
Installed housing and started bottom bolt
Removed “guide bolt”, replaced with top bolt.
Snugged bolts, to hold, cut rubber bands.
Tightened bolts
Wanted to let it sit 24 hours, was 36 by the time I got to it again.
Filled with coolant, “burped” and go.

Now, on to the other 99 problems I got, but a leaky thermostat housing ain’t one!

I’m pretty sure holding the thermostat in place and waiting for a full cure on the sealant was what made the difference, but perhaps the Motorcraft gasket too versus Felpro ? Any way, this part is done now. So happy to take kids for a ride in it today.