Need Help/Advice - Dropped Nut in space thermostat is mounted in

[MA Ranger]

While replacing the thermostat on my '94 Ranger (2wd, 3.0 L V6) today, I accidentally dropped a 1/4" nut (it's about 1/4 in thickness, 3/8" in diameter) down into the space where the thermostat is mounted in the engine. It initially wound up behind the "column" that the bolt on the left side of the thermostat housing goes through ( I could feel it with one of my fingers, but couldn't get a good grip on it to pull it out). When I tried to get it with a bent coat hanger, I some how managed to push it deeper into the cooling system and couldn't feel it anymore.

I haven't attempted to start the truck since this happened - I don't want to damage the water pump or cause a clog in one of the "water passages" in the block and risk seriously damaging the engine. A mechanic I know told me the only way to prevent serious damage at this point is to remove the intake manifold (removing all the requisite parts first - fuel rails, distributor, etc.) and hopefully I will find it, but I may have to pull the cylinder heads off too. He agreed that I could cause serious damage to the engine if I didn't find and remove the nut.

Don't know if this, or something similar, has happened to anybody else - I would appreciate any advice/help I can get. I'm going to work on taking the intake manifold off on Monday. I have a Haynes manual and a local mechanic that can answer questions, but I'll be doing 99% of the work. I plan on taking pictures of everything and labeling everything as I take it apart. Thanks again for all the help in the past - hopefully this will turn out good too.

 

[bilzy7]

Idk... I can only say try a magnet to grab it with but... May be too late.

 

[Earl43P]

I'd remove the thermostat, reinstall the housing, remove the top rad hose and put some screen in the hose outlet to rad to catch the nut.

Run it. It should pump it right into the screen, otherwise your plan is sound, but expensive.

 

[Sasquatch_Ryda]

My thermostat fell apart in my 97 3.0L, and all the bits were just sitting in the intake. I'd get a flexy magnet and go fishin

 

[MA Ranger]

Thanks for the posts. I thought about it some more after I got home last night - I don't think I moved the nut very far from where I initially felt it (in fact, I think I may have moved it towards the front of the engine more). It was right behind the "column" that the bolt for the left side of the thermostat goes through. I don't think there are any passages that go down deeper into the engine at this point since it's near the opening for the upper radiator hose (although the Haynes manual doesn't go into much detail). It is on the opposite side from the outlet for the water pump (thank God).

So, before I try "major surgery tomorror, I'm going to eye-ball the opening that the thermostat sits in/area where I initially felt the nut and go after it with a much stronger magnet than I tried using on Saturday. Thanks again - will post an update soon.

 

[bilzy7]

Good luck. I am troubleshooting p0304 code... Misfire cylinder 4. It better just be the spark plug, wire, coil pack, or that I need an oil change. All I'm doing soon as I'm done with... Currently negotiating the release of a couple chocolate hostages.

 

[MA Ranger]

Thanks for all your posts. I wound up taking the lower intake off the truck and found the nut to the right of the thermostat housing (facing the truck) in the lower intake. I took the lower intake to a machine shop to fix the bolt holes for the thermostat housing. Everything is back together now and the truck runs but it has issues... (at least it doesn't leak antifreeze around the thermostat housing anymore). More posts to follow in the 3.0L forum.