First, using a straigh edge, make sure the housing is straight and not warped in any way. If it isn't, then I would recommend using a quality RTV adhesive designed for waterpump and thermostat repair. Sometimes when you get an aftermarket o-ring, they just don't quite fit right. Also, when you tighten it, are you trying to keep equal torque on each side of the housing? You want them pull the housing on straight and evenly.
Let me know what you find.
Joe
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Thursday, January 14th, 2010 AT 6:08 PM