Thermostat & Seals Kit – Fits Johnson Evinrude 5-235 HP (Replaces 5005440, 8330720, 777260)

Thermostat & Seals Kit – Fits Johnson Evinrude 5-235 HP

This thermostat and seals kit is designed for a wide range of Johnson and Evinrude outboards from 5 HP to 235 HP, covering models manufactured between 1959 and 1995. It ensures proper engine temperature regulation for optimal performance and longevity.

This kit is a direct replacement for multiple OEM and aftermarket part numbers, offering a reliable solution for maintaining your engine's cooling system.

• Compatible with Gasoline fuel types.
• Engine mount installation.
• Constructed with a Marine Grade Brass housing for durability.

Part Number Cross-Reference

Use this table to confirm equivalent part numbers across OEM and aftermarket brands.

Compatible Engine Models

Confirm your engine model/year in the table below. For Johnson/Evinrude owners, here’s a guide to help you identify your engine’s serial/model: Johnson Serial Number Guide.

Technical Specifications

Package Contents

• 1 x Thermostat (Replaces 5005440)
• 2 x Gaskets

Installation Guide

1. Safety First: Ensure the engine is off and cool. Disconnect the battery cables.
2. Drain Coolant: Place a container under the engine and carefully drain the cooling system.
3. Locate Housing: Find the thermostat housing on the engine block.
4. Remove Housing: Unscrew the bolts holding the thermostat cover in place and gently remove it.
5. Remove Old Parts: Take out the old thermostat and any existing gaskets or seals. Note their orientation.
6. Clean Surfaces: Thoroughly clean the mating surfaces of the housing and engine block to remove any old gasket material or corrosion.
7. Install New Parts: Place the new thermostat into the engine, followed by the new gaskets/seals as required. Ensure correct alignment.
8. Reassemble: Re-install the thermostat cover and tighten the bolts to the manufacturer's recommended torque specifications.
9. Refill System: Refill the cooling system with the appropriate coolant.
10. Final Checks: Reconnect the battery. Start the engine and let it warm up, carefully checking for any leaks around the thermostat housing.

Troubleshooting & FAQ

Q: How do I confirm this thermostat kit will fit my engine?
A: Please review the "Compatible Engine Models" table and the "Part Number Cross-Reference" section on this page. It is crucial to match your engine's model, year, and horsepower. If you are uncertain, compare the product images to your existing part before purchasing.

Q: What temperature does this thermostat operate at?
A: This thermostat is rated to open at 143°F (60°C) to regulate engine operating temperature.

Q: What are the common signs of a failing thermostat?
A: Symptoms include engine overheating, especially at higher speeds, or the engine not reaching its normal operating temperature (running too cool). A faulty thermostat can be stuck open or closed, both of which can negatively impact performance and engine health.

Q: OEM vs. Aftermarket?
A: This listing is an aftermarket replacement part (not an OEM component). We build to OEM specifications using comparable-grade materials. Production is done in an ISO9002-certified facility, and each batch is inspected for consistent performance.

Q: How fast do you ship and how much does it cost?
A: We offer fast global shipping—typically 5–15 days worldwide—and standard shipping is free. Expedited options are available at checkout depending on your location.

Q: What is your warranty and return policy?
A: This product includes a 1-year warranty against manufacturing defects under normal use. If something goes wrong, contact our support team with your order details. Returns are accepted within our standard return window (unused & in original condition); please see our policy page or reach out for instructions.

Important Notes

• Verify that the product images and specifications match your original part. If discrepancies exist—even if your model is listed—do not proceed with the purchase.
• This product is an aftermarket replacement part and is not an OEM component.
• Professional installation is recommended to ensure safety and optimal performance.

Why Choose JLM MARINE?

• Quality Assured: As a trusted manufacturer for over 20 years, we supply top marine brands globally.
• Fast Global Shipping: Free delivery worldwide in 5–15 days.
• Direct from Manufacturer: Competitive pricing without compromising quality.