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Nah, mine always started pretty well in the cold also. If I did have any issues, they were battery-related, and those should be solved now... Thanks, though.

A heater plug? I'm not even sure what that is...you don't mean like a block heater do you?

Well, after all that drama, turns out I have a bad sending unit and / or temp gauge. I put everything back together and she started right up. Idled in the driveway for maybe 10 minutes and got up to 180 on the gauge. But as soon as I gave it gas to leave it started jumping. 1/4 mile down the...

Yep, that much was plain when I put it back together. But I swear when I took it apart, they had been installed from the same side. I wish I had a picture to back that up. Anyway, Autozone tested the batteries and one was bad. Got 2 new ones at Wal Mart (hey, I buy plenty at Autozone but...

Hmm, I wonder if the Solargizer is messing with the charger?

Here's today's update: I've been charging using a 12-v charger hooked to one battery at a time but without unhooking the batteries at all. The charger now thinks both batteries are full. Most of the time I've been on 2 amp trickle charge but for a few seconds this morning I tried the 10-amp...

Cool, hopefully that'll turn out to be all my problem was, and the new thermostat and belts are just gravy. :-D Edit: now it seems like the batteries aren't taking a charge. Oy, it's always something!!

Protip: that extra 3/4" clearance makes removal / replacement of the fan about 300x easier. :doh: Everything is back together, just waiting on the batteries to charge.

Crap, yeah, that's what I did. I really thought those springs went on top of the frame. Duh. Sorry / thanks. Edit: yeah, of course that fixed it. Man, even a casual glance at the manual from across the room would have answered that one. Sorry, guys.

Okay so here's the update: Got all the belts on this morning. When I was putting the compressor belt back on I noticed: the locking bolts go in from alternate sides I would swear that originally they were inserted from the same side. Maybe that's why it was loose. I got the lower radiator...

Just heard back from the radiator shop: pressure tested and flow tested fine. I can pick it up tomorrow. Hopefully will put everything back together saturday morning. I'll do my initial test drive with just distilled water and some PEAK coolant system cleaner, then drain again and fill with...

Just as update: I decided to have a radiator shop test the radiator while it's out. They'll hopefully get it back to me tomorrow. Hope to be all put back together this weekend. Edit: Gimpy, your PM box is full. If you need your compressor wrench back sooner than early next week, LMK!!!

No, we had family come stay with us over the weekend and, for some reason, they didn't want to spend time working on it. Some people have weird priorities. But being their host I had to go along with their wishes...

I think this one will be good to go. I'ma try it, anyway.

OK, well, the housing might be OK. Since I had knocked off a bit of the inner lip I went ahead and used the dremel to get the seal out. I pushed out all the lip that was cracked, and maybe 1/3 of it is gone. But it looks to me like I can get a new seal in there and it will seat OK. I think I'll...

Well, crap. That seal is oxidized to the housing and I can't get it out. I tried using a tiny punch and hobby hammer to curl the lip in and separate it from the edge. In doing so I knocked out a piece of the housing itself (the inner ring where the seal sits). I guess now I'm looking for a...

OK, making some progress today. Got the compressor belt off (thanks for the wrench loan, gimpy!) and I'm headed to Napa for parts. WHAT is the trick for getting the old seal (the metal ring with the rubber gasket) out of the thermostat housing body? I've tried needle-nose pliers and hitting...

Hmm I got the seal # 4662.

Yes I did open the block drain yesterday and got some additional coolant out. Alltogether I probably got between 8-9 gallons out, which is pretty close to capacity. Thanks for the pointer on the lower hose I had written down NAPA part 7759 from the resources link above?

Boy if a pinhole leak caused that, maybe my leaky radiator cap IS the culprit. Whoda thunk it? Edit: Thanks, DieselBob!