Changed thermostat housing now runs rough

[Donthekawguy]

Just changed the housing and sensors last week. I took off the throttle body and idler pulley to get it in and out. The inside of the throttle body was filthy so grabbed a can of what I thought was TB and carb cleaner and gave it a doosh. Also when I installed the new housing I notices the sensors were a different size then the stock ones and the passenger side sensor wouldnt plug in. The part that slides in the groove on the plug were in a littlw different spot. So of course I shaved those off to get the new sensor to plug in. Lol now its hard to start and when I push on the gas it stumbles and dies a few times. After I put it all back together is when I noticed the brake cleaner TB cleaner mix up. I think I'll try taking the TB off and checking things out there first but the sensors have me puzzled. The houaing is the correct one just upgraded to the metal one. The new sensors came with it and you would think they would be the same size as the old ones but they are bigger around.

 

[DILLARD000]

...changed the housing and sensors last week
...took off the throttle body and idler pulley to get it in and out
...throttle body was filthy so grabbed a can of what I thought was TB and carb cleaner and gave it a doosh
...sensors were a different size then the stock ones and the passenger side sensor wouldnt plug in
...part that slides in the groove on the plug were in a littlw different
...shaved those off to get the new sensor to plug in
...now its hard to start and when I push on the gas it stumbles and dies
...noticed the brake cleaner TB cleaner mix up
...I'll try taking the TB off and checking things out there first
...sensors have me puzzled
...houaing is the correct one just upgraded to the metal
...new sensors came with it and you would think they would be the same size as the old ones but they are bigger around

GIANT RED FLAGS !!!
Neither your Posting nor Profile say, so assuming you've got a V6~4.0L~SOHC ???
What did you actually spray into the ThrottleBody that was NOT Carb\ThrottleCleaner ???
ElectricalHarness sockets connecting the 2 TempSensors are keyed differently for a good reason; the Sensors are NOT interchangable !!!!
Circuit voltages & resistance ranges of the 2 Sensors are different; one connects to ClusterGauge & the other to the Computer\PCM !!!
Slicing the plastic key(s?) off the Sensor plug(s?) was your 2nd mistake !!!!
What Maker+Vendor is the new Alum ThermoStat Housing & TempSensors; holes may be drilled wrong diameter ???

Click here for more info on swapping from JunkPlastic ThermoStat Housing to Aluminum ThermoStat Housing.

* TempSensor FordMotorCraft# 3L8z12a648ba\dy1004, Gray2pin~PCMControl, 32f0c=104kOhmDecreasesAsTempRises
* TempSensor FordMotorCraft# 3f1z10884aa\ts390, Brown2pin~ClusterGauge, 32f0c=12kOhmDecreasesAsTempRises
* 2ea SensorClips FordMotorCraft# w706800s303

 

[DILLARD000]

Pictures of your
~ old housing
~ new housing
~ old sensors
~ new sensors
would be helpful here.

 

[Donthekawguy]

Unfortunately I already tossed out the old housing and sensors. I usually dont screw up this bad. lol

 

[Donthekawguy]

06 4.0. Both sensors looked the same like the one on the left. I knew something was wrong when neither one of the old ones fit in the new housing. Guess I'll just take it apart again and replace the housing with a plastic one with another set of sensors. Tried to upgrade to metal and shit the bed. lol Also it was brake cleaner I used on the TB.

 

[DILLARD000]

We all have bad days; I certainly do.
Don't give up on installing an Aluminum ThermoStat Housing; just don't buy from that same Vendor.
I actually later plugged the ClipMount hole for the Gray (PCM Controls) Sensor,
bought an equivalent ThreadMount Gray Sensor & drilled+tapped a new hole,
so that Sensor was not so tightly located under the ManifoldThroat & not in the way of changing the OilPressurized TimingTensioner.
Also found that a lite smear of RTV on Sensor ORings\Threads makes them seal much better.

 

[Donthekawguy]

Pretty frustrating since its such a pain to do and by the time I got it all apart I was frustrated and should have walked away after finding the sensor didnt fit. Lesson learned. I'll have to wait to fix it for a couple weeks to fix it and not try to rig it if I dont get the right parts I got it from partsgeek and it probably wouldn't have been a big deal to return it.

 

[Donthekawguy]

Any job worth doing is worth doing twice. lol

 

[DILLARD000]

I'll take PartsGeek off my list of vendors on my wiki page for this.
Your hard learned lesson may save the next guy from the same problem.