Ford Mustang (1999-2004) Service Manual: Thermostat - 3.8L

Material

Item Specification
Gasket Adhesive TA-6 or equivalent WSS-M2G408- A
Motorcraft Premium Gold Engine Coolant VC-7-A (in Oregon VC-7-B) (yellow color) WSS-M97B51- A1

Removal and Installation

1. Drain the engine coolant. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section.

2. Disconnect the upper radiator hose from the coolant hose connection.

Thermostat - 3.8L

3. Remove the thermostat housing.

  • Remove the bolts.

Thermostat - 3.8L

4. Remove the thermostat.

  • Clean and inspect the water outlet connection.
  • Discard the thermostat gasket, and clean and inspect the mating surface.

Thermostat - 3.8L

5. Clean and inspect the thermostat mating surface at the engine.

Thermostat - 3.8L

6. NOTE: The thermostat is indexed and must be returned to the original location.

NOTE: Coat the new thermostat gasket with gasket adhesive.

NOTE: Make sure the new O-ring gasket is secure around the thermostat.

To install, reverse the removal procedure.

7. Fill the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section.

    Heater Core Backflushing
    Special Tool(s) Flush Kit 164-R3658 or equivalent Drain Kit 164-R3662 or equivalent Material Item Specification Motorcraft Premium Cooling System Flush ...

    Thermostat - 4.6L(2V)
    Material Item Specification Motorcraft Premium Gold Engine Coolant VC-7-A (in Oregon VC-7-B) (yellow color) WSS-M97B51- A1 Removal and Installation 1. Drain the engine coola ...

    Other materials:

    Transmission Fluid Drain and Refill
    Special Tool(s) Automatic Transmission Flush and Fill Machine 211-00018 Automatic Transmission Flush and Fill Machine 199-00010 or equivalent Material Item Specification MERCON V Automatic Transmission Fluid XT-5-QM M ...

    Engine (Disassembly)
    Special Tool(s) Impact Slide Hammer 100-001 (T50T-100-A) Remover, Crankshaft Rear Oil Slinger 303-514 (T95P-6701-AH) Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH) Remover, Crankshaft Vibration ...

    Installation
    1. Inspect the rear axle pinion flange seal journal for rust, nicks, and scratches prior to installing the flange. Polish the seal journal with fine crocus cloth, if necessary. 2. Lubricate the rear axle pinion flange splines. Use SAE 75W-140 High Performa ...