Water Pump roadblock.

[GojiraFJ60]

No advise other than when I start to get agitated is when I break things by pressing ahead.
Maybe take a breather and reattack later.

Also, I have battled this with my 40 and needed a replacement thermostat housing. That aluminum is easy to mess up the threads

Here's one for sale for cheap.

For Sale Thread 'N.C. - FJ60 2F thermostat housing'

Jan 1, 2026

Thermostat housing from an FJ60 2F for sale. Good condition.

$50 plus shipping

• R.K.
• Replies: 0
• Forum: Classifieds - Engine/Transmission/Transfer Case

• 

I’m just trying to really figure out what the heck is up. Because it’s like, I’ll take bolts out, put them in til hand tight, and when use my ratchet, 2 of them will be secured, or even three of them.

Here’s a question: are the holes on the upper half supposed to be threaded?

 

[cruiseroutfit]

I’m just trying to really figure out what the heck is up. Because it’s like, I’ll take bolts out, put them in til hand tight, and when use my ratchet, 2 of them will be secured, or even three of them.

Here’s a question: are the holes on the upper half supposed to be threaded?

No, uppers are just thru-bolts. How long are the bolts your using? Should be 8x1.25mm thread x 45mm long.

 

[GojiraFJ60]

No, uppers are just thru-bolts. How long are the bolts your using? Should be 8x1.25mm thread x 45mm long.

View attachment 4059330

Okay, I’m just troubleshooting.
And those are the exact bolts that @cruisermatt sent me.

 

[cruiseroutfit]

Okay, I’m just troubleshooting.
And those are the exact bolts that @cruisermatt sent me.

Bolts are not an issue then. Do you have a 8x1.25mm tap? If not swing by a parts store and grab one and give them a quick clean-out.

 

[cruisermatt]

corrosion in the upper housing holes preventing the bolts from fitting properly?
How about some pics of your upper housing.

 

[S.CarolinaFZJ80]

I’m just trying to really figure out what the heck is up. Because it’s like, I’ll take bolts out, put them in til hand tight, and when use my ratchet, 2 of them will be secured, or even three of them.

Here’s a question: are the holes on the upper half supposed to be threaded?

Perhaps the bottom thermostat housing was cross threaded and you chased one set of threads?

Can you get a photo that shows the threads? Also clean out the threads with brake clean just in case something I.e. part of a thread or debri is clogging a thread

Those housings are fragile and the steel bolts threaded into aluminum are prone to corrosion.

 

[GojiraFJ60]

Bolts are not an issue then. Do you have a 8x1.25mm tap? If not swing by a parts store and grab one and give them a quick clean-out.

Yes.

Bolts are not an issue then. Do you have a 8x1.25mm tap? If not swing by a parts store and grab one and give them a quick clean-out.

I have a tap set.

corrosion in the upper housing holes preventing the bolts from fitting properly?
How about some pics of your upper housing.

I’ll take some photos.
I’m not sure how much more this gasket can take though once I take it off. This’ll be the third time.

(Scratch what I said about M10s.)

 

[Spike Strip]

After that last post, we need pix of old bolts and new bolts side by side and pics of bottom housing

 

[GojiraFJ60]

After that last post, we need pix of old bolts and new bolts side by side and pics of bottom housing

I’ve got stuff everywhere; give me a sec…

The bolts aren’t M10s (I have all of the old bolts for the pump and housing in the same bin; I know, not organized.), so they are 8s; the ones Matt sent over to me.

I’ll take the top half off and get some photos…
And the tap I used matched the 8s. I did make sure of that.

 

[Spike Strip]

No worries.

Your gaskets should be ok as long as it's not torn, but a new one is cheap if you want to get one just in case.

Any auto parts store should have it

FEL-PRO Engine Coolant Outlet Gasket 35307 $3​

 

[GojiraFJ60]

No worries.

Your gaskets should be ok as long as it's not torn, but a new one is cheap if you want to get one just in case.

Any auto parts store should have it

FEL-PRO Engine Coolant Outlet Gasket 35307 $3​

Well, I tried being gentle with it and it tore, so there’s that.

 

[GojiraFJ60]

Old vs new bolts.
Lower housing.

 

[GojiraFJ60]

Upper housing

 

[Spike Strip]

If there's an Oreilly's near you,

AISIN THP109 is both gaskets for same price

 

[GojiraFJ60]

If there's an Oreilly's near you,

AISIN THP109 is both gaskets for same price

I’ll worry about the gasket later. We just need to figure out why these bolts aren’t all fastening at the same time LOL.

 

[UniquE]

I replaced the upper and lower housing, upper is still available but lower not. Seems like I got the last one back 5 months ago

 

[Spike Strip]

New Bolts look fine and same size/pitch

Problem most likely is in the bottom threaded holes being messed up or some cross threaded.

Clean the RTV off the housing ( you used way too much), and gently run the M8 x 1.25 thread chaser - MAKE SURE THE THREAD CHASER goes in perpendicular to the housing. Clean up the threads after that,

Then, WITHOUT the top housing, see how the bolts thread in. They should easily thread in with no binding and should not be floppy in the hole.

New or good used housings are available, but let's see if you can salvage this one, first.

 

[GojiraFJ60]

I replaced the upper and lower housing, upper is still available but lower not. Seems like I got the last one back 5 months ago

View attachment 4059362

View attachment 4059363

I don’t particularly have a problem replacing the housing IF that’s what it comes down to. I just would’ve liked to have this done and doing some final runs this weekend I guess that’s just how this works…

 

[cruisermatt]

I wouldn’t recommend using sealant on those gaskets. A *very* thin coat is acceptable if you have problems with the gasket not sealing dry but the amount you used is way too much. You don’t want the excess floating around your cooling system.

We have new upper and lower housings, gaskets, all in stock here and I could have whatever you need to you next business-day, but I suspect you just need to run a 5/16 drill through your upper housing holes

 

[GojiraFJ60]

I wouldn’t recommend using sealant on those gaskets. A *very* thin coat is acceptable if you have problems with the gasket not sealing dry but the amount you used is way too much. You don’t want the excess floating around your cooling system.

We have new upper and lower housings, gaskets, all in stock here and I could have whatever you need to you next business-day, but I suspect you just need to run a 5/16 drill through your upper housing holes

Fair enough. I guess on the next try, I just do without it. Or just apply MUCH less.