300TDI Thermostat Housing Repair - Defender Source
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Old March 9th, 2014, 11:18 AM
sjpin
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Scott P
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300TDI Thermostat Housing Repair

I was driving yesterday and steam starting coming from the engine. I stopped and popped the hood. The whole area was covered in coolant. It looks like the top of the plug that is on the top of the thermostat housing broke off and coolant was coming from the new hole. I am a newbie at this stuff. Is there any magic to this repair other than getting the broken plug out and putting in a new o ring and plug? Also, any good suggestions on getting the old plug out? I was thinking of a screw extractor. A picture is below. Thanks in advance.
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  #2  
Old March 9th, 2014, 12:20 PM
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leastonce
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Jason England
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Quote:
Originally Posted by sjpin View Post
I was driving yesterday and steam starting coming from the engine. I stopped and popped the hood. The whole area was covered in coolant. It looks like the top of the plug that is on the top of the thermostat housing broke off and coolant was coming from the new hole. I am a newbie at this stuff. Is there any magic to this repair other than getting the broken plug out and putting in a new o ring and plug? Also, any good suggestions on getting the old plug out? I was thinking of a screw extractor. A picture is below. Thanks in advance.
Buy a brass replacement ... I would have thought a suitably large screwdriver lightly tapped into the hole would be able to turn that out.
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Soapy water / KY jelly, etc. is is basically a must. Yes, good idea to remove trim panels - only takes 5 more minutes to do so.
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Old March 9th, 2014, 02:57 PM
sjpin
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Scott P
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Thanks Jason. I got the old one out easily with a screwdriver and I am going to order a brass plug replacement tomorrow.
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Old March 9th, 2014, 06:31 PM
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leastonce
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Jason England
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Clean it up well and make sure the new O-ring sits well and don't crush it when you tighten the new plug!
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Soapy water / KY jelly, etc. is is basically a must. Yes, good idea to remove trim panels - only takes 5 more minutes to do so.
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