Art - Just replacing the Thermocouple would not,/should not increase the length of the pilot flame significantly. Perhaps, it had been low for so long (prior to replacing the Thermocouple) it just seems unusually high (long). You didn't mention whether you're using Natural Gas or Propane Gas. But, the length of a Natural Gas Pilot Flame is normally 2" to 3" long. A Propane gas pilot flame is normally 3/4" to 1 1/2" long. If your heaters pilot flame is falling within these parameters for the specific gas type, you're fine.
Hope this helped you.
Thank you, but what I am getting when I light the pilot is "more like lighting a burner". I have stopped all repairs until I learn exactly what's causing this problem...Natural gas,,, Art
Art, if the pilot flame is wavering rather than coming out straight and engulfing the thermocouple, then it's a pilot problem, not the thermocouple. There may be a problem with the gas pressure or the gas control valve. With that said, you're doing the right thing in waiting for a gas technician to take a look at it, Just for my own information, where did you obtain the new thermocouple you installed? Hope you have a good day and please be kind enough to rate my responses to you. Thanks!
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