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I'm in the process of installing Vortec heads on my motor. The stock temp sensor will not fit the hole in the heads (sensor is too big). Any recomedendations on a sensor that will fit and would work with the stock temp gauge?
I have the same problem, I'm thinking of taking my current sensor to an autoparts store along with a multimeter and doing resistance tests on ones that will fit in the Vortec heads. I might be wrong about this but I figure if I can find one that has the same amount of resistance at room temperature, then it should be close. Another alternative is to install the old sensor in the intake, I think there is a hole in the Vortec Performer that it will fit in. It won't be as good as having it in the head, but it should be close.
Here is what I did last year, I had the same problem with my brand new ZZ4 crate engine.
Go to Autozone and buy a WELLS temp sensor part # TU5 it is a replacement 1/2" temp sensor used in the stock 350 L-48, cost is $5.99
Take the new sensor to a machine shop or to a friend that has a lathe, turn down the threaded area only down to 0.671" diameter.
Next buy or find somebody that has a 3/8"-18 npt. die (pipe die cuts a tapered thread). Thread the sensor while still in the lathe and use the tail stock to guide the die straight.
Thats it you are done, works like a charm.
I experimented on a couple of old temp sensors that I did the same thing to and then cut the open, there is plenty of material left.
My gauge seems to be working properly last summer, with a 180 deg. thermostat my gauge read between 180 to 200....
Ulf