Hi John, Sorry I didn't read your article last night but have read it just now. Really wish I had put a call out before I started the installation. You've gone through almost exactly the same process as me including thinking I had cross threaded the temp sender. Having put it in three turns I thought the thread was wrong and the part must have changed over time. I actually removed it, tapped the hole and put a bolt in it thinking that I just won't have the temp reading. I would also have seen how the piece of foam fits in. Like you I was pleased with the way I worked through the install and hopefully if I go for a test drive today I won't see any leaks. I've printed it off and will put it in my folder. Thanks for taking the time to send it and to everybody else for their tips and offers of assistance.