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Unread 08-18-2011, 02:08 PM   #16
Alfons
Registered User
1992 YJ Wrangler 
 
Join Date: Jul 2005
Location: Ontario, Canada
Posts: 2,218
On those engines that have no hole tapped for the sender unit, the boss is still there and can be drilled and tapped. I did this on a 2005 4.0 engine block - the hole is for a 1/8" NPT thread. If you decide to drill and tap, be careful not to turn the tap too far into the hole while threading because you'll end up with a loose fit. This is tapered pipe thread, designed to give you a real tight fit when done right. When you drill the hole, it'll open up into the coolant cavity below the boss - any bits of metal that fall into this cavity that you can't retrieve with a magnet will disintegrate in the coolant eventually without harming the engine.

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Unread 08-18-2011, 08:21 PM   #17
PFCLinscomb
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1994 YJ Wrangler 
 
Join Date: May 2011
Location: Lafayette, LA
Posts: 120
Quote:
Originally Posted by Alfons View Post
On those engines that have no hole tapped for the sender unit, the boss is still there and can be drilled and tapped. I did this on a 2005 4.0 engine block - the hole is for a 1/8" NPT thread. If you decide to drill and tap, be careful not to turn the tap too far into the hole while threading because you'll end up with a loose fit. This is tapered pipe thread, designed to give you a real tight fit when done right. When you drill the hole, it'll open up into the coolant cavity below the boss - any bits of metal that fall into this cavity that you can't retrieve with a magnet will disintegrate in the coolant eventually without harming the engine.
Nahhh I'm not comfortable with tapping a hole in the block.

But I'm going to just get the Hi-Flow thermostat housing Max suggested, much less work. lol
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