1996 Montero sr thermostat housing... and revival

[spacecowboy7777]

Seized bolt broke when I tried to take out the thermostat. Pics attached.

Is the thermostat housing replaceable? How big of a job am I looking at? Will it be easier to remove the radiators/grill and drill out the bolt? How f$&$ed am I?

 

[spacecowboy7777]

Looks like I can get another thermostat housing (part # md302949 ?). I have a 1995 montero ls parts car available to me. I'll check tomorrow to see if they appear interchangeable.

Does the intake manifold have to come off to get at the part?

 

[Salonika]

You need the factory service manual.

 

[spacecowboy7777]

downloading the service manual now. for those who don't know:

http://www.mitsubishilinks.com/

diagram on page 499. I'm not seeing part numbers for the thermostat housing though

 

[Salonika]

I’d try drilling them out first. Drill it, then spray it with penetrating oil, then use a mini butane torch to heat it while you try and turn it out with an easy out.....I love those little torches because they allow you precise control of where you are adding the heat. Not sure how tight your work area is, get a little right angle drill if space is tight. Just one broke off?

 

[ARDOR]

Use your VIN # to determine part #s here - https://partsouq.com/

 

[spacecowboy7777]

Thanks guys. I was able to get the housing off of my parts truck easily and it looks like it will work. Won’t know for sure until I get the part off of my sr.

the bolt goes through the housing and threads into a piece on the lower intake manifold. The bolt is broken off and seized in the housing itself. I got the housing free and it wiggles, but is stuck in place because of the seized bolt. Trying to cut away the housing and weld a nut onto the bolt now. It’s really stuck. Trying to avoid taking the entire manifold off.

not much space to work with. First nut sheared off when we put torque on it. I had to go to work but my brother is working on it now. Update to come

 

[spacecowboy7777]

Use your VIN # to determine part #s here - https://partsouq.com/

Thank you, this is great. Just used it to identify and order the correct housing and gaskets. I'm sure I'll use it a ton going forward with this project.

 

[spacecowboy7777]

My brother got the housing off without getting the bolt unstuck... I don’t know how. So far it looks like the threads are not stripped, but worst case I have to helicoil it.

Parts truck housing is wrong. New parts ordered.

Also, aluminum powder in the cooling system and on timing belt. The plan is to shop Vac it out then do a few flushes, think I’ll be ok?

 

[spacecowboy7777]

Update: placed an order for the part from an online Mitsubishi warehouse that said it was in stock. Few days later order is cancelled due to the part not being in stock... Repeat 3 more times with three separate venders.

Going to have to find a junkyard part

 

[Salonika]

Unfortunately this is in the cards for all of us eventually......

 

[socalnative]

How well does your heater work?

 

[spacecowboy7777]

How well does your heater work?

wouldn’t know.Got this truck as a project. I’ve seen it run for very short periods of time only.

 

[socalnative]

The potential issue is that your heater core is clogged.

 

[spacecowboy7777]

Saved by Earlron! He lives about 40 mins from me and came through with a replacement housing, thank you!

Installed with a new thermostat:

One of the top threads is stripped, so I added some silicone and will give it a day to cure before adding fluid and giving a try.

Still need:
Battery
MAF
Figure out Ignition switch problems