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Replacing thermostat #1064875 10/14/13 03:37 PM
Joined: Mar 2004
Posts: 360
Lou Offline OP
Mudrunner
Sportage 2000. Needs a new thermostat (I spent last winter with a cardboard in front of radiator).
Naturally...steel bolts into an aluminum casting.....of course they are seized.
So..was able to unscrew the center one, but the front one, even with progressive back and forth motion...just snapped off. Anyway these two can be drilled through and replaced with nut and bolt...because there is room under. BUt the last one, engine side, MUST go out..no bottom access for a nut. So....how is the experience of others on this matter.

....for the time being, I'm going to let the 3rd one alone ...not searching for trouble...and go with the nut and bolt solution for the first two....and reinstall my piece of cardboard....

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Re: Replacing thermostat [Re: Lou] #1064876 10/17/13 05:11 AM
Joined: Apr 2011
Posts: 326
Peabody Offline
Mudrunner
I had 2 holes in the housing strip out on the driver's side (US driver). I ended up running bolts up from the bottom and putting the nuts on top of the housing because, as you have found, there's no room to get a nut underneath. The third bolt has been holding up (passenger side... if I remember correctly). I guess if that one strips out, you could possibly drill it out and replace it with a helicoil thread insert, if they make them that small. Or you could just tap it for a slightly bigger bolt. If all else fails, it's off to the bone yard for a replacement housing... <img src="/forums/images/graemlins/patriot.gif" alt="" />


1997 Sportage 4x4, auto-trans, Warn manual hubs, 4" UPYOURKIA front lift, TJ 106AA rear springs, 2-5/8" body lift, 31x10.50 treads, SmittyBilt SRC front and XRC rear bumper, swing-out tire mount, OBX LSD front diff, Track Finder rear locker, 5.38 R&Ps and... really crappy gas mileage! <img src="/forums/images/graemlins/shiner.gif" alt="" />
Re: Replacing thermostat [Re: Peabody] #1064877 10/18/13 09:19 PM
Joined: Apr 2011
Posts: 326
Peabody Offline
Mudrunner
Just took a look at my thermostat housing. I was off a bit on my recollection. There are 2 bolts on the passenger side of the housing, one of which is a blind hole - the one closest to the timing cover. The third hole is on the driver's side (left) of the vehicle. The two thru-holes can be drilled out and the bolts run through from the bottom, then placing nuts on the topside. There is sufficient room on top to get a hold of the nuts with an open-end wrench or a thin-walled socket. As for the blind hole, it can be rethreaded with a helicoil insert or possibly retapped to a slightly larger size thread. I just checked to see if the helicoil inserts come in small metric sizes. They do. M6 and M8 threads are in the product line. Here's a link to the product in the Grainger catalog.

Hope that helps... <img src="/forums/images/graemlins/patriot.gif" alt="" />


1997 Sportage 4x4, auto-trans, Warn manual hubs, 4" UPYOURKIA front lift, TJ 106AA rear springs, 2-5/8" body lift, 31x10.50 treads, SmittyBilt SRC front and XRC rear bumper, swing-out tire mount, OBX LSD front diff, Track Finder rear locker, 5.38 R&Ps and... really crappy gas mileage! <img src="/forums/images/graemlins/shiner.gif" alt="" />
Re: Replacing thermostat [Re: Peabody] #1064878 10/24/13 09:30 PM
Joined: Mar 2004
Posts: 360
Lou Offline OP
Mudrunner
Seen from the left fender.
[Linked Image]
The bolt near the engine (right) is the one at risk. The center one could be removed..and reinstalled but the threads ..in the aluminum casing...are almost gone...it needs to be replaced similar to the last one on the left, that is, drilled through and replaced by nut and bolt


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