At 08:56 AM 12/3/1999 EST, you wrote:

>Here is what I have experienced on the leaking around the coolant level
>sender:
>1. The expansion tanks get hairlined cracks around the sender hole and leak.
>2. The sensor gets a stress crack in the side of it from someone putting it
>on too tight (happens a lot).
>3. Both.
>
>Upon installing the sender, just remember that it is Plastic, going into a
>Plastic Tank.  No need for 75 ftlbs of torque.  I just snug it (mechanic's
>experience), not super tight, as this can cause more problems than if it
is a >little loose.
>
>Ken Wilford

Amen:

When I had a sensor crack at the top of the thread I band sawed it in half
& discovered that there is only ~1/16" of material between the corner of
the 'cup' that surrounds the two pins & the outside threaded area (less
plastic = more profit from replacement parts?)

1)  get a brand new sensor; turn it uppside down & swab out the cavity with
alcohol + q-tips.  Fill the cavity with epoxy (JB Weld), let it cure &
install per 2) below;

2)  With a new o ring, a little silicon grease (dielectric grease from
FLAPS), & assuming the tank itself is OK where the threads + o ring sealing
area are, then use *only* thumb & forefinger to tighten (enuf to compress
the o ring into the tank groove, *no more*).

Austin