I'm pretty sure I have a warped Thermostat housing on our '05 R53. I replaced the Thermostat about 6 months ago and it's leaking again. I've read many accounts of the plastic pieces warping -

Does anyone make an improved, nonplastic replacement? There's obviously a need but I've looked all over and can't find diddly.

I know I've also heard mention that the factory replacements are now "improved" but how are they improved? Do they still warp?

In the informed opinion of the real wrenches here, do you think it's necessary to replace the thermostat and gasket again since it hasn't been installed very long?

Thanks guys and gals
D

 

My 2004 MCS has 92K. No coolant leak. In preparation for some comprehensive maintenance I went to the dealer parts counter; he talked me out of buying a new housing; said all that I should need is the thermostat and the gasket. Others on this forum think differently, apparently, but I'm not inclined to replace the housing unless it is obviously the source of the leaking.

 

it looks like it is at this point. I replaced the thermostat and gasket with factory parts six months ago, so i'm pretty sure it's not the problem