Now I'll be happy if I can just get the Tank on the road before the next snowfall. I just wanted some warm air blowing through the cabin on cold mornings. I didn't think I was asking for much. The engine temp gauge on my 91 FJ80 reads just a hair below dead center once the engine warms up. Doesn't matter if it's 70 degrees outside or 30 below. Doesn't matter if I've been running around town in traffic for hours, climbing mountains in the summer heat, or doing 70 on the highway. The temp gauge won't move until I stop the vehicle and it cools down, and I'll never get more than warm/cool air blowing inside, front and back.
I figured I'd replace the thermostat. I figured it's an easy job, not expensive, and I could flush the system and check the connections on the sensors at the same time. I had a small pinhole leak in my radiator, so I figured I would fix that up, too, while I had it drained. That's what I figured.
So I began to remove the upper thermostat housing. Then I broke the temp sensor. Then I broke the cold start injector time switch (whatever the hell that is). I broke a bracket trying to move it out of the way. I somehow managed to lose 3 - three! - bolts when they fell through the engine compartment and never reached the ground. And then I broke the 4th bolt off inside the lower housing.
On Tuesday, I'll take that lower housing to the machine shop and hope they can help me. If they can, I'll put everything back together - carefully! - and install the new sensors, coolant, and thermostat. I don't really expect that I'll have interior heat when I'm done, as the thermostat I took out looks like it was replaced just last year (before I bought the vehicle). But as long as it runs, I'll count my blessings and bring a blanket on my next ride.
I don't really have a question, just wanted to vent. But if I have to justify this post, let me say thank you to all of you who have contributed here. You positive comments and boundless knowledge gave me the confidence I needed to start this project.
I figured I'd replace the thermostat. I figured it's an easy job, not expensive, and I could flush the system and check the connections on the sensors at the same time. I had a small pinhole leak in my radiator, so I figured I would fix that up, too, while I had it drained. That's what I figured.
So I began to remove the upper thermostat housing. Then I broke the temp sensor. Then I broke the cold start injector time switch (whatever the hell that is). I broke a bracket trying to move it out of the way. I somehow managed to lose 3 - three! - bolts when they fell through the engine compartment and never reached the ground. And then I broke the 4th bolt off inside the lower housing.
On Tuesday, I'll take that lower housing to the machine shop and hope they can help me. If they can, I'll put everything back together - carefully! - and install the new sensors, coolant, and thermostat. I don't really expect that I'll have interior heat when I'm done, as the thermostat I took out looks like it was replaced just last year (before I bought the vehicle). But as long as it runs, I'll count my blessings and bring a blanket on my next ride.
I don't really have a question, just wanted to vent. But if I have to justify this post, let me say thank you to all of you who have contributed here. You positive comments and boundless knowledge gave me the confidence I needed to start this project.
Thank you for making me feel much better about my limited wrenching abilities. 
