The intake dimensions for the Thermastat opening never changed, If that's an aftermarket T-stat housing (looks like one to me), I'd suspect, it's dimensions are non standard and off spec for what it should be. Try a factory T-Stat housing on the intake, I'll bet it fits.
I called around and couldn't find a factory one. Motorcraft sells one for $90 and I heard thats close to factory specs so I'll give it a shot.
ouch 90 bucks man, i think i would go to a napa or oreilly's and look through the book and find one that will work, a 5.0 is a 5.0 im sure you can find one that will work, you can always use a different upper hose
You can't get a good used one at a junkyard ? Or anywhere else ? I take the aluminum factory ones and polish em to better match the intake.
just an update on this thread . . . $90 tstat housing installed. It definitely was a better design, slightly narrower which I think made all the difference . . . at least so far no leaks. This is the overhang I had before. And this top bolt was stripped enough that I needed to heli-coil it. LOOK at that overhang!! Removed the hoses Here is the new housing It's hard to see but I had to removed the tensioner to get good access to that top bolt that was stripped I took the tensioner off and used a 21/64 drill bit on an angled pneumatic drill to drill out the hole. Used tape on the drill bit to mark my max depth. Then used the thread tap that came with the kit for a 3/8th 18 heli-coil kit. We decided to get 1/4" longer bolts. So from 1.5" and 1" to 1.75" and 1.25" This is the tool that let's you screw the threads into the hole. Then there is another little chizel that you tap once to break the end of the threads off. Here is a good pic of the threads inserted. Here it is installed. Used some silicone and installed the t-stat with the gasket on it so it wouldn't move. So far no leak. I'll keep checking it.
