Replaced T-Stat leak....now new leak at hard pipe. Issues. How to resolve?

[B72011]

I over torqued my Tstat bolts I think and crushed the sealing washer..resulting in a small leak. So I got a new Tstat installed it and wrapped it all up. Tried to install the hard pipe with a new O ring of course...and it wouldn't go in. I jockeyed the pipe from the firewall, couldn't get it in. Lubed it up with straight, slippery coolant...still wouldn't. So I persuaded it in with the tapping of a hammer. Looked fully seated. Drove it, no leaks, now out in the driveway...she's lost a bunch of coolant out of that area.
Anyone else ever have a ton of difficulty getting the hard pipe in? When I did it with the TBelt the first time she went in smooth..this time not so much!
Solutions? Suggestions? New Oring with RTV gasket sealer?
I'm gonna try it again but I don't see anything changing unless I do something really different.

[Alucard136]

Is it a oem tstat? Ive removed mine several times and never had this problem. I always remove the two bolts holding the hardpipe next to the manifold so i can flex the hardpipe. You should be able to push it in by hand

[B72011]

Right? It should just go right in. Yes, I removed the single weird xyz bolt and the two nuts.....really able to move the pipe all over but it was binding weird, that necessitating the hammer tap

[B72011]

I'm thinking if it won't just slide right in (the hard pipe and new Oring) --how about I add. Small layer of RTV sealant to the inside of the Oring to hold it in place...let cure..this effectively will glue the Oring to the hard pipe. After setting ..add a thin layer of gasket sealant to the outside of the Oring...then tap into place. The gasket sealant will help to lube it into place and then when gasket dries..it'll crate a nice, waterproof seal. If it won't work by stock methods, we must try other avenues. Otherwise it will be limp it to a German shop where they will bend me over for $150-200 and finish the job in less than an hour.

[B72011]

Any ideas? Anyone have the same trouble getting the hard pipe back into the t stat?

[Alucard136]

It seems like you have nothing to loose with your idea. Is it an ome tstat? Im thinking so you dont have the wrong tstat.

[B72011]

Yes, I learned my lesson a long time ago....OEM on all mission critical parts! I got it from GAP. My old one was fine it turned out, it just needed a new o ring since I over torqued the sealing oring.

It seems like you have nothing to loose with your idea. Is it an ome tstat? Im thinking so you dont have the wrong tstat.