I've had the t-stat housing extension off quite a few times. I've used a thin layer of RightStuff Gasket Maker every time I've reassembled it and haven't had a leak - not a drop. It's a lot easier than making a gasket and cheaper than buying one. You just need to make sure you don't use too much because the squeeze-out will reduce the opening of the coolant passage. That gasket maker is great! <img src="/forums/images/graemlins/kewl.gif" alt="" />

1997 Sportage 4x4, auto-trans, Warn manual hubs, 4" UPYOURKIA front lift, TJ 106AA rear springs, 2-5/8" body lift, 31x10.50 treads, SmittyBilt SRC front and XRC rear bumper, swing-out tire mount, OBX LSD front diff, Track Finder rear locker, 5.38 R&Ps and... really crappy gas mileage! <img src="/forums/images/graemlins/shiner.gif" alt="" />