I've just about given up on this damn thing! I've replaced the gasket and re-torqued the bolts three times but it still leaks! Anyone know why this is happening?!?!

 

replace the housing..

 

Mine did the same thing until I replaced it. The stock aluminum one will warp after a while and leak. If you go to a parts store the aftermarket is a cast steel but it does not look as nice as the factory.

 

The OE housing from the dealer runs around $15 and IS nicer looking. Also get the gasket from the dealer, the AC-Delco is a printo-seal type, it seals and doesn't leak the first time. For the extra couple bucks it's worth it.

 

Make sure that both the surface of the manifold & the thermostat housing are smooth & all of the old gasket is gone.

I have also found that adding some sealer in addition to the gasket sometimes helps, but I often have to tighten up the housing bolts a few days later when there is a little leak.

I did notice Saturday when I picked up some parts, the guy at Oreillys showed me a chrome housing that would not use a gasket, as it had a rubber O-ring instead, & he said they also sell replacements for those.

 

I had the same issue. I just took the aluminum housing, 220 sand paper, a flat surface and slowly sanded the housing till it was true again. You will notice the sand marks will start on the outside edges of the holes and work there way to the middle as the housing becomes flat again.
just a thought,
Mark

 

Thanks guys! Once again the TGO community has gotten me through another repair!

-John