Gaspi101

Thanks to many of you here at the forum, I've successfully swapped my 96 GT manifold for a 2003 with the aluminum crossover. However, I'm very hesitant to drill into the aluminum to tap another hole for the coolant temperature sensor. SO, I bought a brass tee fitting and hooked both the temperature switch and the coolant temp sensor to it. (see pictures) Good news is the coolant temp sensor seems to do its job, and the fan turns on at appropriate intervals. Bad news is the temp switch is barely reading temperature, and I get zilch on the dash display. I need help deciding what to do. Here are my ideas. Will any of them work? 1. Buy the sensor/switch (2-in-1) that the 2002 manifold goes with, and attach all FOUR wires (2 from each sensor plug) to the same. 2. Relocate the temp switch (BUT WHERE, and most importantly, HOW!!)--I have one idea: I've cut off the coolant tube going from the manifold to the heater core, and plugged it. Could I put the switch here? It won't be in an aluminum housing (as it should be), but clamped to a rubber hose. Will this correctly read the temperature? 3. Leave the damn thing alone and pray I don't overheat.
Barring all of these, I guess I'll have to tap that hole after all. But if I *%&$ up the drilling, I'll RUIN the manifold. If anyone can give me good instructions on how to go about this, PLEASE! As soon as I'm done, I'll post all the pictures of the project here. Again, thanks in advance to all of you mechanics!!!!

Gaspi

Picture 1: Tee fitting w/sensors attached
Picture 2: Place where hole for coolant temp sensor should be tapped.

mustang_montana

when i had my 03 manifold put in i had the shop doit, they took it to a machine shop and drilled the hole no problem and put the sensor in works perfectly. it was like 30$ to get it drilled. i say get it drilled by a shop, that way if they mess it up they buy you a new intake. i mean, this way you could get it done in no time without messing around with wiring or switches and such.

Gaspi101

Need an alternative--manifold's already in....will see---thanks!