440 thermostat housing won't seal ?

John it is a shame I had to force you into helping out. I know it is easier for you just to throw out the smart a.. comments.

I had the same problem. I started with the MP chrome neck - mistake. It warps very eaisly. I got a steel water neck, sanded it flat on a belt sander and installed with the hardening type permatex as insurance. Problem solved.

The iron, heavy aluminum and steel water necks seem to work fine if all parts are flat. One key: don't overtorque. It can warp the flange and cause a leak.

I have a 67 coronet R/T convert that has the same problem.I tried different factory housings and steel replacements and it still leaks.I checked all surfaces with a straight edge,tried different gasketing material still leaked.What I was thinking of doing was having one of my aluminum necks machined to accept a rubber o ring sealed thermostat like most of the newer cars use.

I'm still having problems with my Valiant. RT66Jim (member here) asked if maybe I'm having a problem with the radiator cap.

My problem is just sitting there it will seal. For 2 weeks with the cap on. I'll fire it up for the first time after putting in the thermostat housing back on and let it fun...no leak. Come out the next day and it's leaking. Once it starts leaking nothing that I do will stop it unless I take it back off. Take it off put another gasket, maybe another thermostat housing and it will do it again.

Well, after Jim said something about the radiator cap....after the first run of the motor getting up to operating temp....I'll let the motor cool down crack the cap and it hasn't leaked since.

There is still a problem.....for me. I shouldn't have to do that. But it's building too much pressure after I run for awhile and the cap isn't able to get rid of it I guess.

Anyways I'm saying this for maybe food for thought.........

Good luck, let us know some of the things that your try please?

Just my $0.02:

Flat. Smooth. Clean. Has to be these.

Flat...the opposing surfaces are in contact at every point (or reasonably so). Excludes: warped, curvy, wavy, distorted by excessive torquing of fasteners, etc. Cast iron resists all of these better than aluminum or steel plate. Check in many directions with a true straight edge and 0.001" "feeler" gauge. Or against a surface plate. Or using machinists layout blue. Or even maybe using an extremely thin film of light oil.

Smooth...no nicks, scratches, gouges, pitting, etc. that connect the coolant with outside. The pressure of the hot coolant is constant when the engine is running. Even a tiny channel will eventually give the coolant a way to get through. Gaskets, sealers, etc can only do so much if the parts don't fit or aren't smooth and clean. Yes; epoxy it on and it probably won't leak, although if they are mismatched, even epoxy might give up after a while. Things that don't fit will vibrate at different frequencies and in different modes when clamped together.

Clean. If its smooth it should be clean.

oops forgot one: if its cracked somewhere, it may not be leaking at the joint. tiny crack can seep and be real hard to find...

Sorry for the long...hope it helps...good luck, I know it can be frustrating.

I too had that problem. I don't have any fancy tools, so I purchased some thin cork gasket material from NAPA. Made a thermostat housing gasket. Put a little Permatex on it. Never a leak since.

Can a cast iron housing be mild

Make sure both housings are flat first and then if not make them flat before any thing else
There always reasons they leak, finding and fixing them is the hard part

Just an FYI: we have had issues with the one sided self stick gaskets that a lot of parts stores are selling. They start leaking after install. Another source is to make sure the hose surface on the housing and ID are both clean. I have had more than one hose leak make me think it was the gasket. Lastly a good idea to retighten the clamps (worm gear) every so often until they take a "set" .

Like many I have tried all the tricks trying to get a stock housing (both used and new) to seal including having a machine shop check and mill both surfaces.

Some attempts lasted longer than others but they all eventually leaked.

Thankfully the car is not a stock type vehicle so I spend a little extra $$ and bought this billet aluminum O ringed housing and have never had a leak issue since (4 years now)

I've had the housing off a few times and it has been leak free every time even with the same O ring and never use any sealant.

Somebody should make a stock looking T stat housing with an O ring.

https://www.summitracing.com/parts/bsp-90820

must be flat. clean with brake parts cleaner . apply this --> https://www.permatex.com/products/g...kers/permatex-optimum-grey-gasket-maker/ lightly tighten the bolts when still wet , wait 30 minutes to tighten it down. you could probably lift the engine without the bolts in it.

I was assembling the aluminum intake on my 340 this Winter and found that my cast thermostat housing leaked just after I put in the coolant and let it set overnight. So I took a file and cleaned up the bottom side of the cast housing, then reapplied a new Felpro gasket with the Permatex (waterpump/light blue) sealant. It leaked again after sitting overnight. So I took it off again and used another new Felpro gasket but this time I used the Right Stuff sealant on the mounting surface and the blue sealant on the bolt threads, and it has not leaked a drop.

Note: When I had the intake off for cleaning/paint, I lightly filed the thermostat mounting surface and found it to be fairly flat.

In all my years, I don't think I have EVER had a t stat housing that did not have a leak, no matter HOW much I cleaned and made sure things were flat, etc. . . . . went with this :

http://www.terrysautolab.com/

Have not had a single leak with this !! . . .Yay O ring seals !! . . . I am not too worried about "non stock" look, so for me this was THE SOLUTION !! . . .well worth the $$$

Good luck . . .

grey permatex