How to remove the thermostat housing that connects to the water pipe on a 2.5 V6 Chrysler 1996?

Answer 1

Remove all the bolts in the housing. Two are a little difficult, one is under the distributor and needs removed with a pivot extension or similar flex wrench. The other is under the heater supply pipe to remove this one you first must remove the bolt holding the heater supply line. The bolt holding the heater supply line is attached to the block behind the distributor (not the same bolt as under the distributor). Once the bolt holding the supply line to the block is removed the supply line can be wiggled out (just a o ring holds it now). Once the line is removed the last bolt is accessible for removal. Also the 2 electrical connections must be disconnected along with removing the thermostat inlet cover. Once all this is done the unit can be wiggled off the inlet pipe which is in back of the housing ( all that is holding it now is the o ring in back). Once free from that water pipe (which goes to the water pump and passes under the intake manifold) there is one more line that goes to the heater core that needs wiggled free. This line is also held by a o ring and will separate with a little wiggling of the housing. The housing is now free and can be slipped out from behind the hoses and wires. A leak can develop from the o ring in back this will leak down from on top of the transmission and is probably why you want to remove the housing) . If replacing this o ring make sure you sand the seat clean and use a good RTV sealant on and around the o ring.