For the second time I've had to replace my thermostat housing. Getting to it is a royal pain. Got it all back together and it leaks around the sensors. The o-rings look to be built in and impossible to remove, is the only option here buying new sensors? Anyone else dealt with this problem?

Truck is a 2004 Ranger XLT with 4.0 V6.

this is why when we quote this job at work...we quote EVERYTHING

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2021 F150 5.0 Screw

Past:18 F150 2.7, 16 F150 5.0, 14 F150 5.0, 07 F150 5.4, 03 Ranger 4.0

Master Certified Ford Parts / Warranty Admin

Yeah had to drive to town to get a replacement bolt to hold the thing on also. It's been a huge pain in the rear.

This is getting to be a bigger pita by the minute. Now lost one of the metal clips to hold the sensor in.

yea...we call that the jesus clip for a reason...

jesus where did that clip go

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2021 F150 5.0 Screw

Past:18 F150 2.7, 16 F150 5.0, 14 F150 5.0, 07 F150 5.4, 03 Ranger 4.0

Master Certified Ford Parts / Warranty Admin

Took me over an hour to find it. Had to push truck back and dig through grass. Got it all back together and there is still a little leak, but it was minimal. I'm going to ride it for a bit and see how it goes, have a 3 hour drive today.

I put 2 of those plastic housings in over a 2 month span last summer, they they all failed at the seams, but one I also had issues with the sensors leaking. Tried brand new sensors and everything but turns out it was the housing causing the issues, so I ended up just using a double thinner sized O-ring on the sensor that was leaking. After the second plastic housing failed I got fed up with it and found a guy online that makes aluminum housings and haven't had a single issue since.

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06 FX4 daily driven project truck...

I saw the aluminum housing on ebay, I'm going to order one of those when this one fails. Still a terrible design, would have been more sensible to make a sensor that threads in instead of using those clips.