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Thread: Thermostat housing crossthreaded - solder?

  1. #1
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    Question Thermostat housing crossthreaded - solder?

    My 200tdi (from a disco1) is in a bad way at the moment. Took the temp sender out to put in a different one - suit my new gauge. But it seems that the last sender was not the correct thread; someone has just rammed it on in there, I'm surprised it sealed (maybe it didn't). After removing the housing from the engine I saw what was wrong and thought that just the first couple of turns were buggered, so decided I would try just removing these threads. No go.... and after I did some research found out that the housing is metric. hmmm....

    So the question is the reducer (brass) that my sender needs (for that size hole) is a 3/8 - 18 NPTF to 1/8 - 27 NPTF. This fitting fits snugly into the hole , can I just solder it into the ali housing????? if so how and what do I need to do the job?

    Alternatively does someone have another housing they could sell me?

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    Is the sensor in actual thermostat housing ( the lower part) or in the top half?
    The top halfves are probably still cheap, the the lower part is a rare part and expensive if you can find one

    Forget soldering, although you may be able to get it alloy welded and then re tap the hole correctly, if its not too corroded

    Helecoils are no good for threads that seal on the thread

    You could try building it up with Devcon and remachining. This worked for me on restoring a water pump housing with an ally housing on a RRC V8

    another thought- enlarge the hole and tap it to suit a larger reducer?

  3. #3
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    Bearman is offline TopicToaster Gold Subscriber
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    Quote Originally Posted by Grappler View Post
    another thought- enlarge the hole and tap it to suit a larger reducer?
    That's what I would do Nick.
    Cheers......Brian
    1985 110 V8 County
    1998 110 Perentie GS Cargo 6X6 ARN 202516 (Brutus)

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    Quote Originally Posted by debruiser View Post
    My 200tdi (from a disco1) is in a bad way at the moment. Took the temp sender out to put in a different one - suit my new gauge. But it seems that the last sender was not the correct thread; someone has just rammed it on in there, I'm surprised it sealed (maybe it didn't). After removing the housing from the engine I saw what was wrong and thought that just the first couple of turns were buggered, so decided I would try just removing these threads. No go.... and after I did some research found out that the housing is metric. hmmm....

    So the question is the reducer (brass) that my sender needs (for that size hole) is a 3/8 - 18 NPTF to 1/8 - 27 NPTF. This fitting fits snugly into the hole , can I just solder it into the ali housing????? if so how and what do I need to do the job?

    Alternatively does someone have another housing they could sell me?
    yes i have one here jim
    Russell Rovers
    Series I Parts Specialists
    russellrovers AT gmail.com
    Phone 0428732001

  5. #5
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    It's in the bottom half. the top half would be above the thermostat... wouldn't that give the wrong reading there????

    Anyway I found this stuff HTS-2000, Low temperature Brazing Rods for thin alloys, cast aluminum, zinc, magnesium and nonferrous metals. thought I might give that a go. Just braze the reducer into place.

    Bearman I'm going to send you a PM, if I don't call you.

    Jim - I'm keeping you in mind! Actually if you have 200tdi parts laying around do you have a good condition pipe that runs along the top of the block - for the coolant, rubber hoses connect it to the thermostat housing and the head right now the back. ?
    Last edited by debruiser; 2nd September 2014 at 06:34 PM. Reason: more info

  6. #6
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    I just realised that I never got back to everyone about the brazing rods. I ended up brazing the reducer into the housing, used a small gas torch. Worked a treat and not as hard as you'd think. I've driven 2000+kms with it and got the engine pretty hot a couple times and no issues with leaking or anything so it looks like it's a good permanent fix. Yes the rods are VERY expensive but they work great. I used them on something else.... can't remember what it was now but again they worked well.

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