Hey fellas,

I had a leak in my 94 ED 6 cyl on the lower thermostat housing gasket were it faces to the head. It started slow then progressed to a full blown leak, dripping on to the distributor making it run on "less" than 6 cylinders.

So I changed the gasket this afternoon. I cleaned the two surfaces with a scraper and a very fine sand paper, put on new gasket and replaced the housing.

After filling the car with coolant and water, started her up all seemed good, and it didn't leak. After driving down the road, the car dropped onto less than 6 cylinders, and when I stopped, she stalled. Had a look, and the coolant bottle was "DRY."

Sure enough she's leaking from the bottom thermostat housing all down the side and falling onto distributor.

WHY would this be happening?????

Thanks,

Mark.

the housing is warped best bet is to draw file it with a flat file and use silicone to reseal it

or if you cant be shaged doing that then just head down to the wreckers and pick one up. should cost you less than $10.

also i wouldnt use silicone as such. id recomend ultra blue or black silastic

or get a new one

if they run hot (like over 100) for too long they warp like a b**ch because of the two bolt setup

double check the temp sender.
also try use the pressed metal gaskets.

What Krytox said.
If you are using a paper / card gasket, go to Ford and get
the genuine metal replacement - about $5.
With a little smear of silastic on both sides, it fixed my persistent leak.

Good Luck

Hey fellas, thanks for your replies.

Just letting you know I've finished changing the gasket again on the lower thermostat housing. When I took off the previous gasket (the paper/card one) it was slightly pinched at the bottom, causing coolant to empty out!!

Well, I took the housing off, filed it a bit to really clean the crap off the faces and put a genuine ford metal (probably aluminium, I don;t know) part and put back on. NO LEAKS!!

Thanks again for your quick replies, always rely on FORDMODS.

Cheers,

Mark.

the silicone i was refering to is silastic just another term for it thats all.

good work now i got to do mine as the hew housing i put on a while ago is leaking along with the 8 mnth old radiator