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SOHC 4.0 thermostat housing upgrade


gw33gp

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I will be replacing my thermostat housing. I discovered mine had a partial broken leading edge on the hose port. It is still useable but shows it is time to replace it.

Are there any suggestions as to how to get the right aluminum housing with or without the sensors?
 


DILLARD000

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...replacing my thermostat housing
...broken leading edge on the hose port
...time to replace it
...right aluminum housing with or without the sensors?
@gw33p
Take a close look at your existing Thermostat Housing & answer these questions
* OutletRouting of the TopCoverRadiatorHoseBarb from the Thermostat Housing: RightLo\RightHi\ForeWard?
* Does it have 1 or 2 TempSensors?
* Are the TempSensors ThreadIn Or ClipMount?
Order a full kit with
* 2piece (SKP\RockAuto, TAP\Ebay, AusTek\ZabTek,...) or 1piece (Simmons) Aluminum ThermoStat Housing
* ThermoStatBypassOutlet~PumpInlet ShortBent Hose
* EngineBlock~TStatHousing Rubber ORing\Seal
* TStatLower~TStatUpperBody Rubber ORing\Seal (not required for 1piece Simmons aluminum housing)
* New TempSensors With New Clips If ClipMounted
* TopCoverRadiatorHoseBarb RightLo\RightHi\ForeWard As Needed
* 3 New Engine Mounting Bolts
* 3 New TopCover Mounting Bolts
When you receive the kit & have the old housing out of the truck,
compare the old to new bolts+clips+seals+sensors... use whichever is better.
If needed, now is a good time to also change the SerpentineBelt, WaterPump, Fan+Clutch, Radiator+HeaterHoses, HeaterValve...
Take your time & do it right. Detailed info with links to vendors at
 
Last edited:

sgtsandman

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I will be replacing my thermostat housing. I discovered mine had a partial broken leading edge on the hose port. It is still useable but shows it is time to replace it.

Are there any suggestions as to how to get the right aluminum housing with or without the sensors?
While you have the housing out, it would be a good time to change the external chain tensioners. Especially the one right behind the thermostat housing on the driver's side.
 

gw33gp

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Ford
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Engine Size
4.0 SOHC
Transmission
Manual
2WD / 4WD
4WD
Tire Size
33"
@gw33p
Take a close look at your existing Thermostat Housing & answer these questions
* OutletRouting of the TopCoverRadiatorHoseBarb from the Thermostat Housing: RightLo\RightHi\ForeWard?
* Does it have 1 or 2 TempSensors?
* Are the TempSensors ThreadIn Or ClipMount?
Order a full kit with
* 2piece (SKP\RockAuto, TAP\Ebay, AusTek\ZabTek,...) or 1piece (Simmons) Aluminum ThermoStat Housing
* ThermoStatBypassOutlet~PumpInlet ShortBent Hose
* EngineBlock~TStatHousing Rubber ORing\Seal
* TStatLower~TStatUpperBody Rubber ORing\Seal (not required for 1piece Simmons aluminum housing)
* New TempSensors With New Clips If ClipMounted
* TopCoverRadiatorHoseBarb RightLo\RightHi\ForeWard As Needed
* 3 New Engine Mounting Bolts
* 3 New TopCover Mounting Bolts
When you receive the kit & have the old housing out of the truck,
compare the old to new bolts+clips+seals+sensors... use whichever is better.
If needed, now is a good time to also change the SerpentineBelt, WaterPump, Fan+Clutch, Radiator+HeaterHoses, HeaterValve...
Take your time & do it right. Detailed info with links to vendors at
My thermostat housing has a right side outlet with two sensors. I am pretty sure the sensors are clip mount. The sensors have those wire clips on them. I don't know about the outlet right hi and right lo. RockAuto only shows one aluminum style (with or without sensors) for my engine anyway. The one with the sensors state it has the clip-in style sensors and the one without the sensors shows the clips. I would rather use OEM sensors and will try mine first. They are not that old.

My bolts are in good condition too and should not require replacement. It looks like they don't come with the O-ring seal and I will need to order that.

I just went through a full guide and tensioner replacement on my 4.0 SOHC engine and that is when I discovered the partially broken outlet tip. I did a lot of the stuff you mentioned already as well as a new Melling high volume oil pump.
 

DILLARD000

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Sounds like you've got it figured out! Keep us updated as you get this installed & running.
 

sgtsandman

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The outlet I got had a plug that was held in with a clip in the unused sensor port. It also came with all the needed o-rings and gaskets to replace everything. It also came with some paper/fiber gaskets. Apparently, there was a potential leak issue that the supplemental paper gaskets take care of. I haven’t had an leak issue since the install.
 

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@gw33gp
PS:
Forgot to note, the old righthand Plastic TopCover RadiatorOutlet HoseBarb may fit the new Aluminum ThermoStat Housing
if you wanted to use that instead of a new Aluminum TopCover, if for some reason the hose routing or clearances are wrong.
 

gw33gp

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Good optional idea but will not work for me. My top cover outlet hose barb is partially broken on mine and that is the reason I need a thermostat housing replacement. From what I have seen so far, the one available from RockAuto should work just fine if my sensors fit it.
 

Fredness

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My 2005 Sport Trac had two sensor holes, one was not used.
Got the Mustang single sensor unit.
Works great!
 

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I don't know why, but this part just got really affordable.

I paid $55 for it with shipping.
 

DILLARD000

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I don't know why, but this part just got really affordable.
I paid $55 for it with shipping.
No longer any excuse to buy new plastic junk housings.
 

sgtsandman

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A heck of a lot better deal than what I paid for it. For what they charge for the plastic one, the aluminum one at $55 is a no brainer.
 

gw33gp

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I finally ordered and received the aluminum thermostat housing from RockAuto. It came with a thermostat installed. Does anyone know if it is a good quality thermostat? I would not like to have to replace it soon after install of the housing. I have a good quality one now (replaced fairly recently) and could switch them but don't want to break open the housing needlessly.

I also can't see what the opening temperature rating is. I like to run the stock rating.
 

cbxer55

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I finally ordered and received the aluminum thermostat housing from RockAuto. It came with a thermostat installed. Does anyone know if it is a good quality thermostat? I would not like to have to replace it soon after install of the housing. I have a good quality one now (replaced fairly recently) and could switch them but don't want to break open the housing needlessly.

I also can't see what the opening temperature rating is. I like to run the stock rating.
If it's the same as the 4.0 in my 07 Mustang, the rating is 192 degrees. I replaced mine with a 180 before installing the metal housing.
 

DILLARD000

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@gw33gp
192f 89c TStat is the FactoryOE rating for your V6~4.0L~SOHC, FordMotorCraft# 2L2z8575aa\rt1167
I'm running a 183f 84c TStat, Stant# 14748 with lower BypassDisc ground slightly narrow so it does not jam\stick open in housing Bypass throat
& to increase maximum opening+flow & take advantage of additional 4CoreAllAluminum radiator capacity.
Best to open up your new Aluminum Housing & make sure of the Brand+Rating that you're putting into your truck.
Likely\anyway need to remove that 1.5"HoseBarb TopCover\Outlet to the radiator to get it installed.
Stant\Gates\Motorad are common name brands. If it does not have a brand & rating on it, then definitely replace it with a known ThermoStat.
Can test in a pot of boiling water with an accurate thermometer to confirm it opens\closes when it should.
Update us on how it goes.
 
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