How to: Replace thermostat with metal one!

[ColdCase]

Thanks for posting this thread. I had to tackle this job in a parking lot yesterday. It took about an hour. The $30 hose clamp tool below that I happened to have in my tool box made handling the hose clamps a breeze. I purchased the replacement water outlet assembly from the local NAPA store, needed one now and they had it in stock for $34. Good quality and included all gaskets and thermostat. Also installed a new radiator hose ($13), figuring I may as well while I'm in there, although even after 12 years, the old one looked good. The plastic tube broke off inside the head, and I spent and extra 15 minutes extracting it. The plastic was very soft and easy to split with a screw driver. I also had to clear some corrosion from the head to fit the replacement tube.

Although it overheated for maybe a minute, the engine or head gasket doesn't appear to be damaged. I will be keeping tabs on the coolant level. Next job is thinking about the valve cover gaskets as a small leak has a tendency to drop on the exhaust manifold making some smoke. Very small leak. Only 80,000 miles on this 2004, which has been in the family since new.