Novak Conversions Jeep Wrangler TJ engine mounts

Gasket for thermostat wont fit

beambraker

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Original poster
Joined
Nov 19, 2024
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Location
texas
I am currently replacing the thermostat and thermostat housing on a 2004 jeep wrangler tj 2.4l. Everything seems to fit like a glove besides the thermostat gasket that came with the thermostat it is to big to comfortably fit into its slot along with the thermostat. I went ahead and put it all together to see what would happen when I took it for a test drive coolant started leaking and the vehicle started to overheat (was not doing that beforehand) does anyone know if I do have the right thermostat/gasket or not? Also both the new and old thermostat have the same tempature of 195f.

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I cant say I own a 2.4, but its obvious there was a typical paper type gasket. There is also a mess of RTV on there as well that MUST be cleaned up or it wont seal. Normally the thermo will sit into a slight machine groove with the pellet end down into the engine as the pic shows. The gasket and then T housing and 2 bolts and you are done. A very thin film of RTV can be used but not necessary. Its always wise to put some anti seize on the bolt threads as well. Rule #1 when shopping at the likes any "parts pro" A/P store. If what they try to sell you taint lookin like the part you took off, walk away.
 
I am currently replacing the thermostat and thermostat housing on a 2004 jeep wrangler tj 2.4l. Everything seems to fit like a glove besides the thermostat gasket that came with the thermostat it is to big to comfortably fit into its slot along with the thermostat. I went ahead and put it all together to see what would happen when I took it for a test drive coolant started leaking and the vehicle started to overheat (was not doing that beforehand) does anyone know if I do have the right thermostat/gasket or not? Also both the new and old thermostat have the same tempature of 195f.

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You have to get the mating surfaces perfectly clean. Careful use of a razor blade. Don’t mar the surfaces. Degrease both surfaces. Fel pro should make a gasket you can pick up at local parts store.
 
I don't see a rubber piece around the perimeter of the stat in your pic.

But I do see a lot of stuff that will not allow the housing gasket not seal properly.
 
Did you use a thread putty or teflon tape on bolts? I had a similar problem first time I did mine. That with RTV solved my problem
 
Novak Conversions Jeep Wrangler TJ engine mounts