I've been working on the 60K maintenance and last weekend I did a coolant flush, replaced all my coolant hoses, and fitted a new thermostat. The truck has been running fine - I topped the coolant a couple times after the flush (no apparent leaks), but it's been full thereafter. I noticed yesterday a small leak at the bottom of the thermostat housing. It was wet in the "valley" directly below the housing - not pooled up, but damp. When I ran my hand under the housing I got several drops on my fingers. Again no apparent coolant loss in the overflow tank and it runs normal temp, but I do smell coolant when I shut it down and get out.

My question is if I put the thermostat gasket on correctly? It's a metal gasket with a ridge on one side and a corresponding valley on the other. It appeard the old gasket had the ridge side towards the block so that's how I fitted the new one. Did I screw up?

 

LOL!!!
Your t-stat housing has a little "nick" in it doesnt it? Where the upper hose goes over the housing.
Mine does, its been leaking like that for as long as I have had the truck, which has just pasted 2.5 years.
You have 2 choices, replace the t-stat housing with a new one, or leave it alone and just check the coolant level every time you check the oil.
It will leak more in the summer when it is really hot and not at all or very little in the winter time when it is cold.
I go through less than half a gallon of coolant a year keeping it topped up.
I am going to replace it but I am going to wait until I need to open the cooling system for something else first.
I really dont want to drive clear across town for a new gasket.

 

I didn't notice any nicks in the t-stat housing and it definitely didn't leak there before (I've had the truck since 2001). 98RoverGuy says to use a thin layer of RTV sealant with the T-stat gasket even though Rave doesn't mention it:

https://landroverforums.com/forum/sh...ad.php?t=24646

I did not use any sealant and now I'm wondering if this is it.

 

I had the same problem, so I ditched the metal gasket, went down to autozone and asked for fel-pro #12994. Fits perfect and not a leak in over 6 months

 

Thanks, I'll go get one and give it a try.

 

You guys are talking about D1? The D2 thermostat is enclosed in plastic Y-shape housing and 3 hoses clamp directly to it.

 

I am assuming he was talking a D1, as this would be the correct set up for one.