Folks,
Thought you might like to know what was found the outcome.  Since I removed
the front exhaust piping (stainless steel studs and nuts!) access to the
thermostat housing was easy; a sawzall cut the allan heads off easily.  Both
bolts came out of the head with fingers only, maybe a Vanagon first.  The
surprise was the poor condition of the housing were it bolts to the head.
The inner lip was eroded away and the oring nowhere insight...truly a
disaster averted.  The new housing is reassembled with stainless steel bolts
all around.

Anyone with a WTB with high miles should put removal/inspection/repair of
the housing high on their to-do list

Just looking at this set makes one chuckle and wonder about the engineering
process that went on in development to come up with this Rube Goldberg.

Say, it must be a misprint in Bentley concerning the tightening torque...it
must be 61 INCH/POUNDS.   What do others think?

Best and thanks,

Chris Hawkins
Lost Nation, NH
91 Westy "Arkle"

-----Original Message-----
From: Chris Hawkins [mailto:lostnat@ncia.net]
Sent: Wednesday, September 17, 2003 7:59 PM
To: Vanagon Mail List
Subject: Thermostat housing bolts, 91 westy

Many thanks for all the assistance...and here we go with another PITA.
Just completed a coolant flush and partial hose replacement.  The plastic
thermostat housing is junk.  All four cover bolts are rust and the bottom
fitting spins; the cover can not be removed.  Next the bleed valve is stuck
shut.  So I buy a new unit from Ken W.  Low and behold the two Allan bolt
heads do not take the 6mm wrench, even when the recess is cleaned before
hand.
What suggestions do you folks have?
One idea is to remove the front exhaust pipes, disconnect the 278 hoses,
carefully cut away the existing thermo house so vice grips can get on the
bolt head.  A good overnight soaking in PB blaster is in order to.
Does anyone know the dia/length of the two Allen bolts required
A search of the archives indicates many despise this poor bit of
engineering, although my situation is not addressed.
Thanks for reading this and responding.

Chris Hawkins
Lost Nation, NH
91 Westy "Arkle"