2004 cab coolant leak problem

[aaronbailey]

Hi,

I noticed a small deposit on the garage floor at about the position of the front of the gearbox and towards the nearside, seemed to be like a light oil!!

I have now put it on stands and I can see a drop of liquid on an aluminium pipe which comes from the top of the coolant header tank and which eventually disappears forwards. Pipe dia. approx 1/2 inch presumably a vent pipe?

Can only be a coolant leak but very minor at this stage. No obvious damage to the pipe but it must be pinholed somewhere.

I intend to pressurise the system to 20 psi to see if I can spot the source and as it looks like a very awkward job to replace the entire aluminium section, I was considering replacing only the leaking piece with some hose and clips.

Has anyone replaced this pipe in situ?

Best regards.

 

[ian_alex]

I had this problem recently, also a 2004 cab by coincidence?
Replacing the entire pipe looks like a complete PITA and the most likely place for a hole is at the metal clip on the vertical section.
I cut out a section from above the clip on the vertical piece to an area on the flat where I could get a straight section and then inserted a piece of appropriate hose. I cut the piece out with a small tube cutter and after cleaning up the ends I used a smear of Loctite sealant on the pipe ends before clamping up with stainless hose clips. No problems so far after approx 1k miles.

 

[deMort]

To replace that pipe is an engine out job .. there is a metal bracket that locates it halfway up on the chassis .. steel and ally .. sigh .. common for them to corrode at that point .

I've only ever replaced these pipes .. if a cut and join can be done as per ian_alex post then it will save you a fortune ..

Manual engine R&R is 8 hours labour .. Tip and closer to 13 ... plus pipe replacement .