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I have replaced the gasket twice and torqued it down and it is still leaking horribly. The vehicle is a 95 Pathfinder.
 

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I have replaced the gasket twice and torqued it down and it is still leaking horribly. The vehicle is a 95 Pathfinder.
I don't know what to say... I'll assume you have the correct gasket size... have you checked for cracks on the housing and block? Did you clean the gasket contact surfaces completely? Did you add silicone to both sides of the gasket? How much torque are you using?... too tight will split the gasket.

Did you install a new thermostat? Is it the right size?
 

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I'd say you have some imperfections on the housing cover, rust pits or something..I took mine to a wire wheel when i had it off..
 

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on my old volvo, the T-stat housing was actually warped

like posted ealier, i had to take a grinder to it

place the housing on a table make sure all edges touch the table top
 

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Is the thermostat in the right direction? ;)
 
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