I was in the process of changing the thermostat in my 1997 960 sedan. One of the torx screws was very tight, and I stripped it out. I then created a new slot by hack sawing across the screw with the idea of getting a flathead screwdriver to get a grip. I made the mistake of tapping down on the screwdriver to set it in the slot, and lo, I cracked the flange holding the thermostat to the block. Now I have to still get the screw out, then remove the flange from the bloak. The power steering pump sits close in so that I think that will have to be removed to get to the lower screws. Directions here would be appreciated. TIA. Ron

 

There is 4 or 5 screws holding the power steering pump to the engine.
Once you got the belt off remove the 12mm screws for the pump.
I think you can get to the housing after that but not 100% sure.

 

I was able to move the power steering unit out of the way as you described. There are five screws holding it to its bracket. Once off I had better access to the thermostat flange top piece that was stripped out. I used a hacksaw to cut the head off. I think the problem was a disimiliar metal bonding between the screw and white metal used in the flange because after I cut the head off, the rest of the screw came out without any effort at all. With the top off, I could release the top two screws attaching the bottom half of the unit to the block. There is one screw on the bottom which I was just able to get to, and it came out without any effort. So now it is out, and I will look for a replacement. Thank you for you help. Ron

 

Your welcome.

They are getting pretty common to break.