ok, well i tried to take off my housing today, and i broke inner bolt...(seems like everyone DOES) well i eventually got that out (thank god) with just some WD-40 and a pair of vise grips... now i need to goto the auto parts store tomorrow and get 2 replacement bolts...

i read on another post by reted that they were 6mm x 1.0, but in fact they are 8mm bolts...

the only problem i see, is trying to put that damn thermostat back in... when i took the old one out it wasnt centered on the opening of the hole and there was a gap in between the edge of the housing and the thermostat edge...but when you try to put the new one in, the **** just slides down into the position the old was was in and it wont sit centered on the opening... its pissing me off... anyone know how to get it to sit still while your trying to bolt the upper housing back on?

 

You are using a gasket aren't you? Leave the toggle pointing upwards and center as best as you can . Use some RTV on both sides of the gasket and tighten it down. They're aluminum so not too tight. Use some anti seize on the bolts as you should on *all* bolts.

 

yeah i got a gasket... i guess it doesnt matter which way the gasket is facing huh? then, since one half is sticky i could use the gasket to stick to the thermostat to try and keep it in place...

which part is the toggle? i was just gonna put it back in there how it was before, with the spring side going in towards the engine and that smooth part facing up...

 

If the toggle isn't there, I guess you didn't get the OEM part. The toggle is at the outter ring, you cannot miss it. That should be on top. I've heard others doesn't last as long so give it a try. The gasket doesn't matter which way is up. Yes, the spring side does down. Let the RTV sit for a couple minutes to gel a bit before tightening or else it'll all goo out. Wipe off excess around the edges and let it set. During that time purge out all the air bubbles from the system.

 

i do have the mazda oem part, but i still dont know what your talking about...

 

On the thermostat, there is a loosely hanging metal with a tiny metal ball attached to it.

 

yeah well, turns out this whole simple project turned out to be a ******* nightmare.... i got the new bolts put everything in, tightened it... but it was leaking from the seal... so i figured it wasnt tight engouh and WHAM!!! i ******* break the lower part of the aluminum housing..... now i have to buy that whole new ****... POS engine... everything is old and breakable.... its pissing me off!!

 

Not to add fuel to fire since you are already
I told you the housing is aluminum. If you were leaking from the edges, you either didn't center it enough or didn't use enough RTV. With your finger run some RTV around the outter edges . When you tighten it, you can wipe off the excess. Remember to let it set for a few minutes. You don't need to tighten it too much to seal it.
Sorry to hear having a hrda time. I've been there before. After I tighten everything up, I get a leak around the edges.

 

i was going to buy some sealant but there was a mechanic there and he said you shouldnt add any kind of stuff like that on that part because when it comes time to take if off if wont come off... oh well going to the local yard and getting a whole used housing for 35 bucks.

 

what kind of mechanic told you that ****? that's a load of ****. RTV doesn't seal permantly, you can always take it off, a little flat head to loosen the seal and a gasket scraper will get anything out. tell that mechanic to mechanic, he is a dumbass.

also, i believe the thermostat housing bolts are smaller on a S5 then a S4. I believe a S4 is a 12mm bolt, and a S5 is a 10mm. Don't worry about the leak, sometimes you have to start it a little bit and see where its leaking from and tighten a little more. Or take out the factory manual and look on the torque specs Have fun.

 

i dont understand though... my bolts were only 8mm and 10 or 12 would definitely not fit...

 

8mm ? That is small. That's about the size of a worm clamp nut. Anyway, the S4 is a 12mm.
Whoever told you that RTV won't come off don't know what an RTV is and you shouldn't take your car there.
When you use the gasket, install thermostat first then gasket. Put more RTV at the bottom of the gasket since the gasket is going over the thermostat and it will fill gaps when you install the housing. Spread some on top and let it set for a couple minutes. When you tighten it down, get it tight and turn 1/4 and that should do it.

 

By the way, after many years of fixing things, it's no use getting mad because you'll end up breaking something else. Take your time.
Everything up front is aluminum so you cannot torque it down too much. Always tighten down evenly on both sides. If you tighten only one side then to the other of course it's going to slide over. 2 things I have with me always is a torque wrench and anti seize.

 

RTV & high temp RTV work great on all accessories except exhaust.
I use a little 4" stubby handle ratchet on most bolts that secure parts mated with gaskets & sealant.