I am having a heck of a time getting my jeep back together after replacing the water pump, thermostat and thermostat housing! I am continually getting a leak around the thermostat housing, I think, or the top of the water pump. I have a torque wrench and torqued the water pump to about 17 ft-lbs and the thermostat housing to 13 ft-lbs (156 in-lbs) as directed in haynes manuel, but still getting a leak. I have had both off double checked that all gasket material has been removed and re applied three different times now (with new gaskets each time) and I still get the same results. Please anyone got any ideas? Thanks!!!
Leaks like that are often cause by not getting the surfaces that the gasket seats against 100% clean. I use nothing but a paper gasket, absolutely no RTV, and if I take great care to get the surfaces absolutely scrupulously surgically clean of all old gasket material, glue, RTV, etc., it forms a leak free seal. Virtually every leak I have ever had was always caused by the surfaces not being 100% clean and free of any contaminating bit of debris, old gasket, etc.
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Also make sure the thermostat is seated right in the housing it likes to get in there crooked and coolant pours out. I like using a tiny bit of Indian head shellac to keep it in place while I snug it down, just a light coat on the block and stick the thermo to it, then the housing over that. Has never failed me, and of course the paper gasket too.
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Yeah I'm sure I'm putting it together correctly. It's a brand new housing so I wouldn't think it would be cracked, but will check. I've actually worked on all of my cars since I was 16 and never had this much trouble. So I'm not new to the water pump/ thermostat, just can't seem to get this one going for some reason. Prob something stupid I'm doing.
Make sure the heater hose coming out of the top of the thermostat housing is fastened securely with a hose clamp. My old hose was crappy and the clamp just couldn't secure it well enough to the housing. This caused a leak that made me think at first that the water pump and or gasket on the housing were leaking.
I put on a new hose and hose clamps. Everything is fine now.
Bump, I'm having the exact same problem as OP. I've reinstalled the t-stat three times now, once with RTV sealant and the housing is still leaking. I even bought a brand new housing, so it's not the housing that's cracked.