03 150 Saltwater EFI thermostat housing

[demarko210]

Captains,

Ok while changing out the port side thermostats i was trying to get my cover back on. What is happening is when i place the cover over the thermostat on the port side the left side screw seems to not want to thread into the hole. When i remove the cover and thread the bolt into the hole its threads fine. Anyone every come across this issue? I will try to grind the housing with a Dremel tool a bit.

 

[Dukedog]

ya might wanna rethink tha grindin' part.. something is wrong when tha right bolt won't work in tha right hole on tha right part.....

did you try any of tha other three bolts in that cover in that hole?

 

[demarko210]

ya might wanna rethink tha grindin' part.. something is wrong when tha right bolt won't work in tha right hole on tha right part.....

did you try any of tha other three bolts in that cover in that hole?

Yes i tried the other 3 bolts to try and fit into that location. Same thing they did not catch the thread. It catches when i just thread the bolt though.
I didnt mean i will grind but just clean up the surface area and see if it helps. Also I will clean the threads on the bolts with wire brush.

 

[Dukedog]

might chase tha threads with a bottom tap....

 

[demarko210]

might chase tha threads with a bottom tap....

I will investigate that. The image is before i removed the thermostat. Looks good but now it does not close the same.

 

[Dukedog]

tha other bolt (same housing) tighten down right right?.. tried without t-stat and rubber?

 

[demarko210]

tha other bolt (same housing) tighten down right right?.. tried without t-stat and rubber?

correct. I just cleaned the bolts with degreaser and wire brush. One bolt had metal thread halfway around the one thread about 1/3 the way up. I did not try with out the rubber.

 

[Dukedog]

ya gonna need to heli-coil that hole more than likely then...

 

[demarko210]

ya gonna need to heli-coil that hole more than likely then...

I am going back over to the boat and clean the housing and surface area and see if i can get better results. I will update in a few hours. Thanks i will look at the heli-coil kits and see if its something i can do.

 

[Dukedog]

gl with it......

 

[demarko210]

gl with it......

So i found the issue. See the image attached. It seems as if the housing is taller on the portside. Can you see the difference? Now i dont know if i should buy a housing and see if they are the same or try to find a bolt.

 

[demarko210]

Fixed it with a bolt from Home Depot. Mercury called for M8 X 25 used a M8 X 30 and it fasten right up. I may take the bolt and paint it to keep the corrosion down. The gunk around the top is the Permatex No. 3 i was using. Moving on to the electronic switches and I will be sailing!

Thanks again.