Hi
doing a flush fill yesterday on my 2000 windstar. I took the thermostat out, cleaned around the housing removing the old gasket etc. When reinstalling, and following the Hayes manual to the letter I ended up with a leak, without even starting. Hmm, that's funny I thought. So, as the housing bolts had a torque range (71 in-lbs to 97 in-lbs) I went to the higher end of the range. Snapped the F***ing bolt off. Luckily I got it out in one piece. Actually I think the head came off as the bolt was bottomed out. This whole situation happened twice. The old "maybe I did it wrong somehow the first time" attitude.
The manual says to mount the thermostat in the engine, place the gasket (with silicone waterpump sealant on both sides of the gasket) overtop and then carefully put the housing on, torque and install the hose, clamp. The housing has a recess, exactly the same size as the thermostat, the engine side does not (but the directions say...) After their method didn't work I had to take methods into my own hands. So, anyway I put the thermostat in the housing, added the gasket and bolted the whole works onto the engine. No leak, driving fine currently.
This whole thing got me to thinking, are there frequent mistakes in the Hayes manuals? Is this just unique to my van, year?
I really don't know a ton about car repairs but I can read, have good mechanical skills and almost all the tools I require due to my day job.
Any thoughts??
Cameron