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Discussion Starter · #1 ·
I've had a leak coming from a round the thermostat housing for over a year now. It's a minor inconvenience but I have to top up every 2 to 3 weeks depending on how fast I drive.

The car has been going so well, I'd like to finaly fix this problem.

I've tried to locate a reasonably priced thermostat housing, but all local scrap yards no longer have Escort parts available. I've done some digging and found a picture and it looks like it may not be made of plastic like I initialy thought.

If that's the case, could it be possible it's just a gasket ?

Is this a comon problem ?

Thanks in advance!
 

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Thermostat housings on the '92 1.9L engines are aluminum...I can't imagine that the '96 1.9L engines are any different...so you probably just need a new gasket unless the housing itself is cracked or warped...might as well replace the thermostat while you're at it...

be careful when attempting the repair or be prepared...the lower bolt holding the housing to the head likes to snap off
 

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I have seen new thermostat housing on NAPA's website. Having said that, I'd prefer one off of a newer Escort, like a 1997 and relocate the two temperature sensors into the housing instead of that stupid tube.

Use this:


Along with the heater hose for a 1997 as well. You might have to splice the wiring for the sensors, but if you know how to solder, that's not a big deal.
 

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Discussion Starter · #4 ·
grampy666 said:
Thermostat housings on the '92 1.9L engines are aluminum...I can't imagine that the '96 1.9L engines are any different...so you probably just need a new gasket unless the housing itself is cracked or warped...might as well replace the thermostat while you're at it...

be careful when attempting the repair or be prepared...the lower bolt holding the housing to the head likes to snap off
Wow thanks for that last bit of information. Maybe spraying some sort of liquid wrench type of product will help ?

If it does break off, is it hard to get the rest of the bolt out ?
 

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Discussion Starter · #5 ·
zzyzzx said:
I have seen new thermostat housing on NAPA's website. Having said that, I'd prefer one off of a newer Escort, like a 1997 and relocate the two temperature sensors into the housing instead of that stupid tube.

Use this:


Along with the heater hose for a 1997 as well. You might have to splice the wiring for the sensors, but if you know how to solder, that's not a big deal.
I just checked the Canadian napa and they don't list it :(

Is the 97 housing a direct bolt up? I'm not that great with soldering, I can do some basic mechanic tasks so I'm very limited.

Thanks for the suggestion though, if I really can't locate what I need at a resonable price, I'll start looking at that for a replacement.

On another note, perhaps I should have asked this in my original post.

How long does it take to change a housing out?
 

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If it does break off, is it hard to get the rest of the bolt out ?
It can be a time-consuming royal pain-in-the-a$$ that, if done wrong, will completely mess up the head or require you to pull the head and take it to a machine shop to get the broken bolt out...

I recently had to deal with exhaust manifold studs broken off and stuck in the head...after messing up one head by trying to drill the broken stud and use an EZ-out, I discovered some "stud and bolt remover" kits at Sears...don't have a pic right now, but they are essentially a hardened-steel die with helical cut threads and splines that you hammer on to the end of the broken bolt/stud...the splines cut 6 grooves in the sides of the broken stud/bolt...then you can slip a socket over the die and get a real good grip to back it out the way it was meant to come out...
 

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If you happen to need a thermostat housing, I would get one at a junk yard, but they are available new at Rock Auto (but too expensive for my tastes).

they do not appear to be a big deal to remove, but better find someone here wh has actually done it for a better guide.
 

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Discussion Starter · #8 ·
grampy666 said:
If it does break off, is it hard to get the rest of the bolt out ?
It can be a time-consuming royal pain-in-the-a$$ that, if done wrong, will completely mess up the head or require you to pull the head and take it to a machine shop to get the broken bolt out...
Alright well that possibility is making me think twice about taking this project on. I have some mechanic ability but if that bolt broke I'd be SOL and I've just looked through the comon problem sticky and that bolt is listed there. Theres a good chance this will happen to me, so I guess I might turn to a mechanic which is what I was trying to avoid.

Thanks for the help guys!
 

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Screw extractors sometimes work as well. The head on them burrows into the stud, then allows you to reverse it back out.

I'll look for whatever Grampy666 mentioned next time i'm in Sears. Never hurts to have these tools around for one of those 'just in case' moments. Trying to do a job without the proper tools, all to often leads to 'disaster'.

zzyzzx, just out of pure curiosity, does that bolt up to the mid-nineties vehicles ?

.... after messing up one head by trying to drill the broken stud ....
A possible idea for dealing with that ? You can probably clean the drilled-out hole, fill it with JB Weld, then use a tap after allowing it to cure. That might've saved you from having to pull the head. Most difficult part after removing remnants of the bolt, would be getting the tap to go in straight.
 

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I'll look for whatever Grampy666 mentioned next time i'm in Sears.
A possible idea for dealing with that ? You can probably clean the drilled-out hole, fill it with JB Weld, then use a tap after allowing it to cure. That might've saved you from having to pull the head. Most difficult part after removing remnants of the bolt, would be getting the tap to go in straight.
Not to hi-jack this thread, but I plan to post pics (including one of the kit I bought) in my autobiography soon...I drilled the first head for an EZ-out and busted the EZ-out off in the hole and things went from bad to worse after that...I wanted to pull the head anyway for a rebuild/overhaul and now it's a "practice" head for port matching and stuff...I just happen to have a whole 'nother 1.9L engine laying around for my '95 LX overhaul project...

now, back to our regularly scheduled program...
 
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