I have a Whirlpool BFG flame lock water heater. Yes I know one of "those". The problem is that the pilot light won't stay lit. I read through the forum and the owners manual and was going to try a few things on my own to get it going again.

First, I was going to clean the combustion chamber and the flame-trap. I also figured I would replace the thermocouple because it was only a $6 dollar part from Lowes. I have a degree in engineering, so I think I'm a pretty handy guy, and this should be easy.

So I got started on my repair and already ran into problems. Using the manual as a guide I followed the instructions for "Removing the Manifold Assembly". I removed the 2 screws securing the manifold door and disconnected the thermocouple from the thermostat. Then I went to disconnect the manifold tube and the pilot tube. Using a wrench and a decent amount of muscle I couldn't disconnect either from the thermostat. Are these things sealed with epoxy?

Anywho I got frustrated and gave up and was going to called a repair man. I decided to put it back together but now the threads of the 2 manifold screws won't line up. I'm sooo aggravated right now.

Any help would be greatly appreciated!!