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I had this issue on an 2005 mustang V6. For the V6 guys, the thermostat became a wear item, replacing it every 30k to 50k miles. They also had a guy that made metal ones, but the cost was so high that you could afford to replace the plastic one like 4 times before it made sense to get the metal one. Mine blew up right before i got home one day, but it was an easy fix.
sad to learn the LT1 engine is using a plastic thermostat housing too. :/
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