FEL-PRO 35041 Water Outlet Gasket Instruction Manual

1. Introduction

This manual provides essential information for the proper installation and maintenance of the FEL-PRO 35041 Water Outlet Gasket. Adhering to these instructions will help ensure optimal performance and longevity of the gasket in your vehicle's cooling system.

2. Product Overview

The FEL-PRO 35041 is an engine coolant outlet gasket designed to create a leak-free seal between the water outlet (thermostat housing) and the engine block or intake manifold. It is manufactured with application-specific materials to meet or exceed original equipment specifications, providing reliable sealing performance.

Figure 1: The FEL-PRO 35041 Water Outlet Gasket. It is a blue, oval-shaped gasket designed to seal the water outlet, featuring a large central opening for coolant flow and two smaller circular holes for mounting bolts.

3. Compatibility

The FEL-PRO 35041 Water Outlet Gasket is compatible with a range of Ford vehicles. It is crucial to verify compatibility with your specific vehicle before installation. This gasket fits:

• 1980-1986 Ford C600
• 1980-1986 Ford C700
• 1980-1987 Ford C800
• 1980-1994 Ford F-600
• 1980-1991 Ford F-600
• 1980-1998 Ford F-700
• 1980-1991 Ford F-700
• 1980-1998 Ford F-800
• 1980-1991 Ford F-800
• 1980-1990 Ford FT800
• 1980-1985 Ford L8

Always consult your vehicle's service manual or a reputable parts catalog to confirm fitment for your exact year, make, model, engine, and trim.

4. What's in the Box

The product package contains:

• One (1) FEL-PRO 35041 Thermostat Gasket

5. Installation Instructions

Proper installation is critical for the effective sealing and longevity of the gasket. Always refer to your vehicle's specific service manual for detailed, step-by-step instructions and torque specifications.

Required Tools and Materials:

• Basic hand tools (wrenches, sockets)
• Scraper or wire brush for surface cleaning
• Brake cleaner or appropriate solvent
• New engine coolant (if draining is required)
• Torque wrench (recommended)

Installation Steps:

1. Safety First: Ensure the engine is cool before beginning work. Disconnect the negative battery terminal.
2. Drain Coolant: If necessary, drain a portion of the engine coolant to prevent spillage during removal of the water outlet.
3. Remove Old Gasket: Carefully unbolt and remove the water outlet housing. Remove the old gasket material from both the water outlet and the engine mating surface.
4. Clean Surfaces: Thoroughly clean both mating surfaces (water outlet and engine) to remove all traces of old gasket material, corrosion, and debris. Use a scraper or wire brush, followed by a solvent, to ensure a perfectly clean and flat surface. Any remaining debris can cause leaks.
5. Position New Gasket: Place the new FEL-PRO 35041 gasket onto the engine mating surface or onto the water outlet housing, aligning the bolt holes. Ensure it is seated correctly.
6. Reinstall Water Outlet: Carefully position the water outlet housing over the new gasket and align the bolt holes. Insert the bolts.
7. Tighten Bolts: Hand-tighten the bolts initially. Then, using a torque wrench, tighten the bolts to the manufacturer's specified torque values in a crisscross or alternating pattern to ensure even pressure. Over-tightening or uneven tightening can damage the gasket or housing.
8. Refill Coolant: If coolant was drained, refill the cooling system to the appropriate level with the recommended coolant type.
9. Check for Leaks: Reconnect the battery. Start the engine and allow it to reach operating temperature. Carefully inspect the newly installed gasket area for any signs of coolant leaks.

6. Function and Performance

The FEL-PRO 35041 Water Outlet Gasket provides a critical seal to prevent coolant leakage from the engine's cooling system. Its design ensures a tight fit, maintaining proper coolant pressure and flow, which is essential for effective engine temperature regulation. The gasket's material composition is engineered to withstand the high temperatures and pressures encountered in automotive cooling systems, resisting degradation from coolant chemicals.

7. Maintenance

Gaskets are wear items and their condition should be periodically checked during routine vehicle maintenance. While the FEL-PRO 35041 is designed for durability, regular inspection can help prevent potential issues.

• Visual Inspection: During routine engine checks, visually inspect the area around the water outlet for any signs of coolant leaks, stains, or residue.
• Coolant Level: Monitor your coolant level regularly. A consistently low coolant level without an obvious external leak might indicate a slow internal leak or a leak that only occurs under specific operating conditions.
• Replacement: If any signs of leakage or gasket degradation are observed, the gasket should be replaced promptly to prevent further coolant loss and potential engine damage. It is generally recommended to replace the water outlet gasket whenever the water outlet or thermostat is removed for service.

8. Troubleshooting

Most issues related to water outlet gaskets stem from improper installation or material degradation over time. Here are common troubleshooting scenarios:

Symptom: Coolant Leak at Water Outlet

• Possible Cause 1: Improperly cleaned mating surfaces.
• Solution: Disassemble, thoroughly clean both surfaces to remove all old gasket material and debris, and reinstall with a new gasket.
• Possible Cause 2: Uneven or incorrect bolt torque.
• Solution: Disassemble and re-tighten bolts to manufacturer specifications using a torque wrench, following the correct tightening sequence.
• Possible Cause 3: Damaged or defective gasket.
• Solution: Replace the gasket with a new one. Inspect the water outlet housing and engine surface for any cracks or deformities that might prevent a proper seal.
• Possible Cause 4: Corroded or warped water outlet housing.
• Solution: Inspect the housing for damage. If warped or corroded, it may need to be replaced.

If troubleshooting steps do not resolve the issue, it is recommended to consult a qualified automotive technician.

9. Specifications

10. Warranty Information

Specific warranty details for the FEL-PRO 35041 Water Outlet Gasket are provided by the manufacturer. Please refer to the official Fel-Pro website or contact their customer service for the most current and comprehensive warranty policy.

11. Customer Support

For technical assistance, product inquiries, or support regarding the FEL-PRO 35041 Water Outlet Gasket, please contact Fel-Pro customer service directly. Contact information can typically be found on the official Fel-Pro website (www.felpro.com).