Leaking Woes

[BlueCobra]

Thanks Macgyver

I did not try that; maybe that is why it keeps leaking. I'll try that when I put it back together.

[MacGyver]

I have fought that battle before only to discover the leak was around the bolt threads. This can happen on t-stat housings as well as front cover and water pump bolts. Be very carefull and check front cover and water pump bolt threads as they can be a bottom casting for the bolt hole causing a hydrolock of sorts breaking the casting when bolts are coated in areas when the hole bottoms out instead of penetrating a hollow. A friend of mine recently broke a chunk of his block off using too much sealer in an area where it wasn't needed. i recommend probing the casting with a pick first. If the hole bottoms out you shouldn't need sealer. If it penetrates into into a water jacket you should definatily seal the threads. A thin coat on all bolts should ensure a good seal regardless.

[STL Mark]

I may have your best answer. I had this same problem this week. I called two different auto parts stores - they had the same question for me, and the same answer for the solution - which has worked. Check this out -

They asked - is you water outlet chrome? I said - why yes it is.
They said it's warped.

I said - it has only 4000 miles on the new engine.
They said - no mater - it's warped.

In disbelief, I removed it and put it on the counter - yep warped.
I installed a plain old cast iron water outlet - and all is fine.

Don't bother with fancy gaskets, or messy glue/sealer - just get a plain cast iron water outlet (paint it if you want) and problem solved - forever.