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Topic: Thermostat housing (Read 863 times) |
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Ellogg
Newbie
I love YaBB 1G - SP1!
Posts: 15
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Thermostat housing
« on: Nov 23rd, 2006, 10:38am » |
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Hello All
I have had my scorpio for 4 years now, all I can say is what a car, anyway of late I have need to top up the coolant water as it keeps dropping and the light comming on on the dash. I have found that there are two cracks in the inlet manifold with white powder stains around, just behind where the thermostat housing is. 2.3 ultima. Do I need a new mainfold, if so is it easy to fit or can it be welded to seal crack(new and second hand) ??
Any help will be great Thanks in advance
Ellogg
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Simmo
Administrator
I'm an OAP !
Posts: 5508
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Re: Thermostat housing
« Reply #1 on: Nov 23rd, 2006, 1:25pm » |
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Ellog. This is the common spot for the 2.3 inlet manifold to go. There have been successful repairs with various materials but the 'jury is out' as to whether it is a long term cure. No doubt a member who has done a repair will be along shortly.
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Jonnycab
Senior Member
Former owner of 2.3 Ultima Facelift saloon
Posts: 3900
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Re: Thermostat housing
« Reply #2 on: Nov 23rd, 2006, 2:31pm » |
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I managed to repair mine back in early September & it's still holding strong after approx 7000 miles. 
The crack ran from the ECT hole to just below the matrix pipe outlet. The brass hex nut for screwing the ECT in had also come out as the crack ran right up to the edge of the plastic (brass hex nut) housing.
I thoroughly cleaned (with meths) & roughened (with sandpaper) then cleaned again the area inside & out, & then took some pics with the digital camera to see the crack better (difficult to get your head in there).
Using a red hot knife (heated with a blow torch), I sealed over the crack inside, & then outside (still taking pics to make sure I'd got the crack).
Then put a fine layer of Quick Steel over the sealed crack on the inside & a generous helping of Quick Steel over the whole area on the outside.
Once the Quick Steel had hardened I wiped some instant gasket around the ECT brass hex nut & pushed it into the hole (had to remove rubber sealing ring as wouldn't go in flush) & held it in with gaffa tape until the instant gasket had set (couple of hours)....also wiped some instant gasket with finger around the inside of brass nut via T-stat opening.
Note....gaffa tape is very strong, so had to peel it off carefully, as it might have pulled out the brass nut. 
Finally another generous helping of Quick Steel around the brass nut to hold it in nice & strong.
Had to be careful not to over tighten ECT when screwing back in, for fear of dis-lodging the brass hex nut again. So used red hermatite on thread & tightened it up very slowly until it felt reasonably tight, did this also on the temp guage sender as well.
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Jonnycab
Senior Member
Former owner of 2.3 Ultima Facelift saloon
Posts: 3900
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Re: Thermostat housing
« Reply #3 on: Nov 24th, 2006, 3:17am » |
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Three pics, showing where mine was cracked....
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Ellogg
Newbie
I love YaBB 1G - SP1!
Posts: 15
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Re: Thermostat housing
« Reply #4 on: Nov 24th, 2006, 7:49pm » |
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Nice one fellas not had a good look just yet at the actual crack but considering an arc weld on it depending on position. I will keep you informed Thaks again everyone
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Geoff_W
Senior Member
98 Ulti2.5tdi Auto
Posts: 1340
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Re: Thermostat housing
« Reply #5 on: Nov 24th, 2006, 10:39pm » |
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Hi arc welding may be a problem, the 2.3 inlet manifold is plastic, which is why Jonny used a hot knife.
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The winding road goes on and on... or at least it does in Northumberland
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