I can't stand the lame coolant reservoir on these trucks. I don't know if they changed the design, but here's what I did on my 04.5...

What do they pay these engineers? I hope it's not much over minimum wage.. You GOTTA' put a bit more design time into the coolant overflow tank, as it's a bit more important than copying a washer fluid tank!!!

So the problem..... Everytime the truck bounces around a bit, I get a good stream of antifreeze/coolant running down the frame and suspension. The reservoir is basically a huge open tank, with a flimsy cap, and no interior baffle blocking the oversize, funnel shaped vent...










So here's what I did..


Grab a 1' section of standard 1" ID heater hose. It should have an approximate 1-3/8" outside diameter..









Cut a small wedge shape at the tip so in can restrict, but not block all flow at the bottom when shoved in the tank..









Shove the hose down in the tank, and look through the center making sure the hose is touching the bottom of the top portion.. About 3-4 inches down..

Now, draw a line around the top, and make an alignment mark/arrow where the existing vent is now...










Measure down and cut a 1/4" x 1/4" vent hole to line up with the vent hole in your tank..










Grab a small self tapping screw and a small drill bit. I wrapped the bit in masking tape and worked it through the tank by hand as it's soft thin plastic..









Drill through tank. Reference location in the next pics...








Slide hose back down in tank, make sure the cut vent hole lines up with the tank vent, and screw in the screw. Once in, cut the hose flush with the top of the tank...









Top view... You can see the hose touches the bottom, but doesn't block the flow..

 

Snap flimsy cheap lid back on and go!!!!




What this will do is still allow you to fill/top off the tank, but the huge amount of splash will have a near impossible time getting up the new hose and out the smaller vent..

 

Don, I have often wondered why my overflow is always a little low, even after being filled to the line. I think you might have solved this for me and a few others. The dealer always shrugged their shoulders and said they don't know where the coolant was going. But that is no surprise. I guess I'll have to look at doing your mod. Thanks, and keep up the good work.

Darren

 

If they'd take 5 seconds and look around they'd see where its going. After a good romp mine always has a few drops on the control arms and fender liner.

 

Nice work!

MikeyB

 

Nice job Don!!!!!!
what a great and simple fix

I am glad your fix was not just plugging the vent off with something.


Nice write-up and pics

 

Oh yeah, good job. You sure are a fart smucker!

 

Thanks all!


So far so good, but I'll do some more romping today just to make sure no splash gets up to the vent.




I forgot to mention...

When you get the hose, make sure it fits tight in the neck as it will also prevent the loose fitting cap from leaking too..

 

Added to the wiki....

http://wiki.dieseltruckresource.com/...olant_Drip_Fix

 

Mike, Shane's got a few write ups that should be in the wiki........wink, wink nudge, nudge....

 

i know i got a few up

 

I did not even know I had this problem

something else to fix

 

add this to my list.

coolant fix
twins
whistler
tranny
sticks

$$$
$$$
$$$
$$$
$$$
$$$

LOL!!

 

Is it really necessary to screw in the tube to the bottle?? I am almost done with this mod and I can't for the life of me see how it might slip down into the tank. It is a snug snug fit and the tube hits the bottom of the plastic neck.. Thanks guys!