203 Thermostat Installation gone Wrong... - PowerStrokeNation : Ford Powerstroke Diesel Forum
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post #1 of 14 (permalink) Old 04-19-2008, 12:31 AM Thread Starter
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203 Thermostat Installation gone Wrong...

Hey guys I just broke a bolt inside the thermostat housing... Any ideas on how to fix it? Can't move the truck until I fix it and it is my only vehicle... Luckily it is the bolt on the most outside corner.

99.5 F250 2wd 6Speed: DP Tuner, Straight Pipe, DIY Tymar, 203 Thermostat. Spec Focus Hauler!!

23.5 MPG (HIGHWAY)
17.5 MPG (City)
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post #2 of 14 (permalink) Old 04-19-2008, 12:33 AM
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Re: 203 Thermostat Installation gone Wrong...

go get a bolt extractor kit should do the trick...

2003 F350 BAMF EDITION
5.9 CR 2.6 Puller
Thanks to
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Drivelines Plus
Industrial Injection
Farmers Machine
Georend Brothers

2008 F350 Daily/BAMF Tow Rig
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post #3 of 14 (permalink) Old 04-19-2008, 01:00 AM
 
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Re: 203 Thermostat Installation gone Wrong...

Quote:
Originally Posted by 03f3507.3 View Post
go get a bolt extractor kit should do the trick...
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post #4 of 14 (permalink) Old 04-19-2008, 03:15 AM
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Re: 203 Thermostat Installation gone Wrong...

I posted this on TDS about a year ago:

Quote:
Hoorah! I now have cab heat!
I ordered the 203* thermostat & housing Thursday early afternoon, it was waiting when I got home Friday evening.
Dieselsite was extremely fast. I had not yet put my wallet back in my pocket before I was getting confirmation e-mails. And believe me, I am very quick about putting my wallet back before any more money jumps out.

A few note for those who come behind:

a) Drive the truck until the engine is as warm as it will get. This keeps your hands from freezing in 0 deg F weather while you work on it.
b)Take the belt off, it is just easier that way. Almost necessary to get the job done.
c) Dieselsite's instructions are really good. Expecially about how much coolant to drain out.
d) A 3/8 hose is really good for directing the coolant into a bucket instead of across the core support and down onto your chest and face. Make a note to install the hose before you open the drain.
e) When the two bolts on the front of the housing break because they are so badly rusted, they are 6.00MMX1.00 bolts.
f) stuff shop rags into the hole where the thermostat was. This keeps shavings and blood out of the coolant.
g) remove the A/C compressor bolts and move the compressor over. You will need the space for the drill.
h) when walking back to the truck with drill, tap, drill bit, and bolt, do not put the drill bit in your mouth to hold it. Remember how you were warned as a little kid not to lick the metal during winter? Well it's not fun to have your face in front of the kerosene heater waiting for a drill bit to warm up so you can remove it without removing large pieces of your lips.
i) Use a punch to mark the center of the broken bolts as closely as you can before drilling. The tops of what remains of the bolts are rough and the drill will not want to stay centered otherwise.
j) Have patience when tapping. This is not the time to get in a hurry and make another run into town, this time for a tap extractor.

I was really starting to hate this truck when my temp gauge not even getting to the N of Normal. Now it runs almost exactly vertical. I'm in love with the truck all over again.
It's too early to tell if I will see any mileage changes, but it seems that the truck responds slightly better.
All was well until I left to go to Phoenix, Az two months later, and about 1.5 hours into the trip the temp gauge started going down. Ever since then it will fluctuate a lot while I'm driving. The only time it doesn't fluctuate is when I've got a good load on the engine. Usually that means at least 8psi at 70mph, where normal cruising is around 3-4psi. I ain't figgered it out yet.

Go ARMY!
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post #5 of 14 (permalink) Old 04-19-2008, 05:58 PM Thread Starter
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Re: 203 Thermostat Installation gone Wrong...

thanks for all the specifics!!! Now I need to find a 6mm x 1 tab... Harder than what i though

99.5 F250 2wd 6Speed: DP Tuner, Straight Pipe, DIY Tymar, 203 Thermostat. Spec Focus Hauler!!

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post #6 of 14 (permalink) Old 04-19-2008, 11:45 PM
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Re: 203 Thermostat Installation gone Wrong...

Quote:
Originally Posted by INFOCUSHAULER View Post
thanks for all the specifics!!! Now I need to find a 6mm x 1 tab... Harder than what i though
Lowes is usually good for specialty hardware if there's one around you. I think I got the tap @ sears.

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post #7 of 14 (permalink) Old 04-20-2008, 03:24 AM Thread Starter
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Re: 203 Thermostat Installation gone Wrong...

Got the tap but can't loosen the belt tensioner... any tips..

99.5 F250 2wd 6Speed: DP Tuner, Straight Pipe, DIY Tymar, 203 Thermostat. Spec Focus Hauler!!

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post #8 of 14 (permalink) Old 04-20-2008, 04:29 AM
 
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Re: 203 Thermostat Installation gone Wrong...

make sure u turn the tensioned in the correct direction. It is a lot easy if u get a belt tensioner tool from NAPA or somewhere like that. I always used breaker bars, but got tired of almost smashing my fingers, so i bought the tensioner tool and it makes it a snap.
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post #9 of 14 (permalink) Old 04-20-2008, 07:27 AM
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Re: 203 Thermostat Installation gone Wrong...


2003 F350 BAMF EDITION
5.9 CR 2.6 Puller
Thanks to
L&L Diesel
Drivelines Plus
Industrial Injection
Farmers Machine
Georend Brothers

2008 F350 Daily/BAMF Tow Rig
Spartan Tuned [email protected] 84.76 1.65 60ft
03f3507.3 is offline  
post #10 of 14 (permalink) Old 04-20-2008, 02:23 PM Thread Starter
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Re: 203 Thermostat Installation gone Wrong...

I'll give it a good try with my 18" breaker bar...

99.5 F250 2wd 6Speed: DP Tuner, Straight Pipe, DIY Tymar, 203 Thermostat. Spec Focus Hauler!!

23.5 MPG (HIGHWAY)
17.5 MPG (City)
INFOCUSHAULER is offline  
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