I plan to replace my stuck-open unit this w/end. I see the instruct at bay13, but was wondering if it's as simple as it sounds?? can someone who did this b/4 give me a time estimate(i'm a little mech. inclined) and actually tools needed. Any short-cuts and things to avoid, etc. oh, its a 97-854 T5. TIA, BD

One of the most easy jobs you'll run into on the 850. 1/2 hour max.

I didn't even bother draining fluid - only a very little spilled.

Enjoy!

As others have already told you, it's pretty simple, and the only potential snag is stripping the bolt. On top of some of the suggestions made, I have one myself. Take a punch, and whack the bolt nice and hard a couple times to help break it free. Another recommendation is, don't use those L shaped torx drivers, use a torx bit on a ratchet or on a screwdriver, so that you can lessen the chance of stripping the head.

The job is really simple, but heed the caution about the T-40 torx head bolt. Here's the problem: one of the bolts is difficult to get a tool on because of interferences. If you have a T-40 socket for a regular 3/8" socket wrench, it probably won't work, even with an extension drive, because it's just too fat to fit. Many people (like me) end up purchasing a long T-handle torx T-40 tool, which is not a common item you'll find in the Craftsmen aisle at Sears. I bought mine from Wiha tools, part 364/T40x200, less than $15, somewhere online.

In addition, if the bolts have never been removed, you'll find that they are on very tight. It can be difficult to get enough torque on the screw with the Wiha tool alone. I used a long screwdriver as a cheater through the hang-hole on the Wiha handle. Since the handle is plastic, it will bend and bend, but eventually I got the thermostat bolt loose.

Gerald C

It is simple. Just drain out enough coolant that you can work on it. Last time I did it, my coolant was fairly new...so I got a clean oil drain plan, dumped the coolant in that, and then funneled it back into the car when I was done.

Only one warning (and Volvospeed already says this) DON'T STRIP THE 30MM TORX. The metal on those screws is very soft. I got them out, but in the end replaced them with some 7mm bolts from a 264 engine that were the same size (hex head). Make sure to torque them back no greater than the torque spec. And of course check for leaks after you're done and have the car started.
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Brandon
95 854T 92k
Pictures =)