Just swap the housing with a new one, put antiseize compound on each bolt
thread, and put it back together.  You won't break anymore bolts, or twist
the thread inserts in the plastic housing!
TEMiller
----- Original Message -----
From: "Don in North Carolina" <vanagondon@GMAIL.COM>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Tuesday, July 05, 2005 6:20 PM
Subject: Changing thermostat on 2.1L - Question?

Oh Great and Noble Listers,

I am about to embark on a great adventure - Oh wait, no I'm not!  I
need to change my thermostat in my '88, and have a question.

How much coolant will be lost with a thermostat change?  In other
words, when I open the housing and pull the old thermostat, will a cup
or two of coolant come out, or will it be like opening the floodgates
of Hell?

This job is already complicated by the fact that the very first bolt I
tried to remove snapped off!  I was using a 1/4 inch drive ratchet, so
it isn't like I was strong arming it, it started to turn (I thought)
and then turned REALLY easy, with that "Uh oh" kind of turn.  The head
and part of the shank twisted right off. <sigh>

I have a new lower thermostat housing (and all new bolts), but I'm
hoping not to need it, if I can get the old bolt out, that is...  Once
I get the top off, I'll see if any part of the shank is available to
turn (I hope!).

--
Don in Reidsville, NC
1986 Kawasaki Concours
1988 Vanagon GL (Sylvia)
"Why do they call it a fixed income, if mine is always broke?"