Fans running a lot??

[K80Shooter]

Post pics of the old thermostat, that could help explain things.

[Lew L]

....
This link shows #2 flat head screw? .....

That screw holds the cooling pump DRIVING gear to the cam shaft...........

To get the the old thermostat I have to cut up the old pump which I'll probably do

Lew L

[Lew L]

.

K80---- you're the winner!!!! I cut out the old thermostat and the "Mystery plug" is part of it. The thermostat is NOT made to come out!! I used a dremel saw and cut the locking tabs as I'll NEVER use the old water pump again. the plug helps center a spring under the thermostat. The mystery is how it got loose????

Now to put it all back together--------------

EDIT: old thermostat worked. mystery plug stopped it from opening to far. Could see wear marks in the right spots and right sizes to stop thermostat expansion. I don't know how it got loose, It's kinda locked in place by a plate and spring.

[trikermutha]

Alright. Solved that mistory..

So the leak has stopped?

[Haze]

Lew, Great detective work and documentation.
We can all learn from your evaluation and explanation.
Thank You.

[Mikey]

Put it back together again and ride the thing!!!!!!!!!

[K80Shooter]

Glad you found the problem. I've saw many thermostats come apart over the years.

[trikermutha]

Must be a odd thermostat versus what I am use to??

[Lew L]

Put it back together again and ride the thing!!!!!!!!!

I sure wish I could. I did put it all together with high hopes---------- and it's leaking out the bottom the the pump housing

[Lew L]

Glad you found the problem. I've saw many thermostats come apart over the years.

Yes---- three extra ( and loose, not attached to the actual stat) pieces including the mystery plug that caused me grief.

[Mikey]

Is it cracked??

[trikermutha]

Is the gasket shifting while you are installing the pump? O ring is still got too?

[Lew L]

Is the gasket shifting while you are installing the pump? O ring is still got too?

Although there is not much room there the pump goes straight in the last 3/8". I'm going to rent a radiator pressure tester from the local auto parts store--- that will tell me more. I have even read about cracked coolant tanks???

[Lew L]

Is it cracked??

The pump housing is plastic BUT very tough. The 5 bolts that hold it in place have a sleeve to stop any cracking and I do use a fairly new in.lb. torque wrench to the correct specs and tightening order. It's a 2 stage torquing like cylinder heads ,ect.

[UtahPete]

Although there is not much room there the pump goes straight in the last 3/8". I'm going to rent a radiator pressure tester from the local auto parts store--- that will tell me more. I have even read about cracked coolant tanks???

Wouldn't those causes be evidenced by leaked coolant?

[trikermutha]

Bring the cap with you when you borrow the tester. This way you know you have the right test cap in the tester. They say 15 PSI to test.

Is it coming from the pump or are you not sure yet?

[Lew L]

./

There are 3 hoses that come out of the coolant tank and 2 are well hidden. I'll top up the tank and pressurize it to see if there is a crack . It is a process of elimination before I pull the pump again.

[Mikey]

You should know for sure where it's coming from before you take it apart again. That way you know what your fighting!

[trikermutha]

Yep one out to the radiators one hose back from the radiator and the tank hose.

[UtahPete]

How is this project going, Lew?

[trikermutha]

[Lew L]

.

R and R the pump again and it still leaked when pressurized to just a few psi. I'm biting the bullet and its going to the local dealer. I hate giving in but I was getting too good at removing the pump and bathing myself in antifreeze ( even with the system drained).

So this summers trips are out but there are more summers ( and fall) to come.

I do want to thank all you guys who helped me through this adventure. A word of advice when it comes the the water pump--------- DON'T........

[trikermutha]

Sorry to hear that Lew. Let us know how it turns out when you get it back.

[Mikey]

I had a leaking pump last year, when I say on the 998 where it was, I didn't even hesitate to throw the white flag in!! I think you did a hell of a job, and look at it this way, you got a little closer to your ride!!!

[UtahPete]

I had a leaking pump last year, when I say on the 998 where it was, I didn't even hesitate to throw the white flag in!! I think you did a hell of a job...

what a bummer...I was hoping for a better outcome for you.