I finally got the courage to replace my head and everything is back together and running great!! Very excited.

Only issue is on my '96 there are two temp sending units, one on the tstat housing and one on the rear of the head. On the new head there was no spot for the rear temp sending unit (which powers my gauge)

I have read that I could drill and tap on the head, and although this would be the best for accuracy its not something that I am brave enough to do.

I am looking at this link for a temporary fix but would like to do something a little cleaner in the long run http://www.jeepforum.com/forum/f11/a...method-990168/

In the newer xj's there are just one sending unit in the thermostat housing that runs the needs of both in mine, would it be possible to upgrade to this and splice the wires together? Any ideas or solutions would be very helpful, thanks guys.

 

I would recommend not splicing any wires together as it could send a false signal to the ECU. Sensors/sending units send a more accurate signal when the tip of the sensor/sending unit is located directly in the coolant flow. I would suggest mounting the temp gauge sending unit in a brass/copper nipple located in the heater hose close to the t-stat housing thus the tip of the sending unit being located directly in the coolant flow.

 

that looks like a great idea, would jb weld work to secure and waterproof the nipple to the pipe?

and this wouldn't hinder any flow of coolant at all would it?

 

There are also other inexpensive options out there that are single piece, pre-tapped with rolled ends.

 

That's JBWeld in the pic. Drill hole slightly smaller than the fitting and screw the fitting in.....the brass is harder than the copper so it will cut threads into the copper. Seal it with JBWeld. If u place the fitting in the heater hose facing down, the sending unit will always be immersed in flowing coolant. This is about as light weight as u can get. Those threaded brass blocks and screw-in nipples get heavy (pull on hose) and expensive. The units in the performance catalogs are $30-$40 vs $3-$4 make it yourself. Don't forget to run a ground wire.

 

great idea, but once you have the fitting threaded in couldn't you just hit it with a torch and some solder? I think I'd feel a little more secure that way, although JB Weld is good stuff. Also, if you're soldering, that gives you the opportunity to solder a brass nut on the copper for a ground wire connection.

 

Sure could.........if I had some solder and a torch. LOL

 

so can i put that here?

 

Yep, the closer to the t-stat housing the better.

 

well i tried lowes and fastenal and they both had parts like in the picture with the right size threading but the sensor wouldn't fit through, idk what to do, any more ideas?

how do people install aftermarket temp sensors, i know a lot of people do

 

A pic is worth 1K words. Got to know what the male thread size is on the sending unit to get the correct corresponding female thread adapter. I think most electrical sending units are 1/8" MNPT or 1/4" MNPT and screw into 1/8" FNPT or 1/4" FNPT adapters. The female adapters are what's JBWelded (or soldered) into the copper nipples and the sending unit screws into the adapters.

 

Temp senders are 1/4" NPT. Oil senders are 1/8" NPT.