I know the head is recessed for the thermostat so I figured it went head, thermostat, gasket, housing.....just can't figure out why it's leaking this bad.

 

Haynes says housing, thermostat, gasket, head. I always switch the gasket and thermostat because I find it easier for thermostat not to slip and lines up easier. It will leak coolant if you don't evenly wrench them down, but on this note, I asked the other day and never got an answer. When you redo this, can you measure the length of the bottom bolt for me. Mine got dropped somewhere in the bay and I'll pay you back with a thanks.

 

Will definitely get a measurement for you on that bottom bolt. If that order is correct, then why would the head be recessed? Shouldn't the housing be recessed if the thermostat is on the housing side of the gasket?

 

The head is recessed because the thermostat goes in that recess , I glue the gasket to the thermostat housing and apply a coat of rvt to the gasket and bolt it up. Be sure the thermostat doesn't slip out of place then you install the housing.

 

I just did the one on my 89 this way. No leaks.

 

I just double checked Haynes, it says to put thermostat in housing. Apply gasket on housing and install cover. I would take a pic of that part and post it, but don't know legal rules

 

It may vary with the motor but my 2.5 YJ and my wifes 4.0 XJ the thermostat sits in the recess in the head , btw don't rely on what a Haynes manual says Haynes and Chiltons amateur repair manuals are grossly inaccurate.

 

You can use RTV or Blue Goo or what ever you want to create the seal. But the order for installation is housing, gasket, thermostat, head.

I normally use what is called high tack for gaskets that are in a "heat area". and I put the thermo in the recess part of the head and then use the high tack on the head side of the gasket, and put it in place. then put the housing on that. The bolts have to be evenly torqued, and its tricky to not let the thermo slip out of place while you are lining things up.

Make sure that both mounting surfaces are clean and dry before you even start the process. Or, it will fail miserably like yours obviously did.

 

Like I previously said, I don't do the way it says

 

Permatex aviation for a gasket on both sides of the gasket, fought my 4.2 in my cj for a week before using this. Also not sure of your engine, but the torque spec was ridiculously low.

 

Another thing just from my experience, those stupid blue gaskets rip easy. I gave up on those a while ago.

 

Jevenson-

The lower bolt is 3/4 in long. I'll try the reassembly when I get home from work tonight. Thanks everyone for the help.