I would machine the housing if you have that much interference. Basically you are trying to seal two "perfectly flat" surfaces but for the fact there is a bulge being created by the thermostat sticking up too far. I just looked at the Motored (Stant) thermostat for the 302 and it measure 1.75mm at the flange thickness and is 54.1mm diameter. What a PITA for sure!
Need cooling help please
- Thread starter SpyderMike
- Start date
I measured the depth for the thermostat on one of my housings, I had .98mm and the thermostat was flush with the sealing surface.
I'd RTV the thermostat to the housing and let set up before assembly so thermostat does not drop between housing and intake.
I'd RTV the thermostat to the housing and let set up before assembly so thermostat does not drop between housing and intake.
I agree that machining would be the best solution if possible at this point. Note that the mounting flange varies in thickness too. How does one machine this thing down the correct amount?
I will be tacking the thermostat down - great suggestion!
I mean the previous install was just sealant without a gasket...it lastest 18+ years. Hmmm
I will be tacking the thermostat down - great suggestion!
I mean the previous install was just sealant without a gasket...it lastest 18+ years. Hmmm
If when you installed this most recent time you had significant leakage, it is more likely the thermostat slipped out of the housing and created the gap. As for machining, you would need someone with a CNC mill. I still never heard how you determined there was a major leak? How was that done - with the vacuum system?
When I pulled it back apart, the gasket still held the thermostat in the housing because I had thin coated both sides (per your suggestion); the thermostat was not displaced.
I pressure tested and could hear and feel the air coming out of a specific location (along the outboard bolt side).
I pressure tested and could hear and feel the air coming out of a specific location (along the outboard bolt side).
The hole in the thermostat gasket is smaller in diameter than the thermostat flange. Therefore the gasket rests on top of the thermostat flange. If that flange is above the housing surface, then the gap in space results in reduced gasket adherence and coverage. It was leaking where the thermostat flange was protruding the most to the minimal recess in the housing in that area. That is my guess....
Man, I will be happy when this simple task is resolved!
Man, I will be happy when this simple task is resolved!
I live in Ohio and am willing to throw the housing on my cnc mill for ya and take it down flush. Just would prefer to have the thermostat as well to measure for correct fit for you.
I'd even run a few test cuts on scrap before screwing up lol.
How can I not take you up on this most generous offer!? Please DM me your address and I will get it out to you. Thank you in advance!
