Intermittent radiator leak

Creakydoor

TJ Enthusiast
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Jul 17, 2018
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Arvada, Colorado
I have had an intermittent leak in my radiator for a while now. Sometimes it happens regularly, sometimes it doesn’t happen for weeks at a time.

The leak manifests itself in showing antifreeze pooling in the bottom of the radiator shroud. If it’s leaking and the engine is running, I also sometimes see the fan sprays it everywhere. It’s not a pouring leak, but it does drip a bit, then stops. I also sometimes see a small amount of antifreeze along the top of the radiator.

A few weeks back, I thought I found it and replaced the upper radiator hose. After that it was fine for weeks so I thought I had nailed it. However a few weeks later it started leaking again, so that wasn’t it.

My suspicion is that the top of the radiator has some small crack on the top and that certain heat or angle (e.g. my driveway is sloped) and it leaks. I’ve attached a picture from the top of the radiator after the last leak and there is fluid there. (Hard to see since the picture is dark.). So, I think it’s time to replace it. It’s the original 21 year old radiator, so it’s peobably time. But I wanted to get a few thoughts from you guys here too.

As far as which to replace it with, I have read enough threads on here that convince me to go Mopar and keep it as stock as possible.

I have a 1997 TJ 4.0L with 5-speed. Based on that, I think this is the right one for me even though Amazon says it’s not right: Mopar 5503 7652AA, Radiator https://www.amazon.com/dp/B0049EH4AC/?tag=wranglerorg-20

Anything else I should consider or investigate before I hit “buy” on Amazon?

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While you have it out, I would go ahead and replace the water pump, hoses, thermostat and thermostat housing. Flush the heater core, and put in fresh Zerex G05 coolant mixed 50/50 with distilled water.
 
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While you have it out, I would go ahead and replace the water pump, hoses, thermostat and thermostat housing. Flush the heater core, and put in fresh Zerex G05 coolant mixed 50/50 with distilled water.
Already had new radiator hoses. So good there. Will definitely get the Zerex G05.

The overall system has 84,000 miles but it’s 21 years old, so probably time to do some preventative maintenance. :)

For the other stuff I’m thinking:

Mopar 5300 6192, Engine Coolant Thermostat Housing https://www.amazon.com/dp/B004VWXH9E/?tag=wranglerorg-20

and

Stant 45359 SuperStat Thermostat - 195 Degrees Fahrenheit https://www.amazon.com/dp/B000C7YRNM/?tag=wranglerorg-20

and

Stant 25160 Thermostat Gasket https://www.amazon.com/dp/B000C847YU/?tag=wranglerorg-20

and

ACDelco 252-279 Professional Water Pump Kit https://www.amazon.com/dp/B000C9KLE4/?tag=wranglerorg-20
 
Already had new radiator hoses. So good there. Will definitely get the Zerex G05.

The overall system has 84,000 miles but it’s 21 years old, so probably time to do some preventative maintenance. :)

For the other stuff I’m thinking:

Mopar 5300 6192, Engine Coolant Thermostat Housing https://www.amazon.com/dp/B004VWXH9E/?tag=wranglerorg-20

and

Stant 45359 SuperStat Thermostat - 195 Degrees Fahrenheit https://www.amazon.com/dp/B000C7YRNM/?tag=wranglerorg-20

and

Stant 25160 Thermostat Gasket https://www.amazon.com/dp/B000C847YU/?tag=wranglerorg-20

and

ACDelco 252-279 Professional Water Pump Kit https://www.amazon.com/dp/B000C9KLE4/?tag=wranglerorg-20

Looks like you're all set then! You must have read the Jeep Wrangler TJ Cooling System Overhaul FAQ thread!

At 21 years old, regardless of mileage, it's definitely time!
 
Mine failed at 92k, 19 years. The OP wasnt very good on maintenance, there was definitely sludge in the reservoir, and the radiator looked pretty corroded on the inside when I replaced it. I overhauled the system in 2016, hoping its the only time I need to do it!
 
On this thread, @tworley suggested getting a new thermostat housing, but on the overhaul thread, it doesn't mention it. @Chris should this be added to the recommended list?

Yeah, I probably should add that to the recommendation list, as it is something I would suggest doing as well!
 
Yeah, I probably should add that to the recommendation list, as it is something I would suggest doing as well!
Also, in looking at prices and shipping from two different Mopar sites, it seems that moparwholesaleparts.com is generally cheaper than wermopar.com. I only mention it because you link to the latter, more expensive one.
 
I checked Amazon vs the link above, and moparwholesaleparts.com wanted about $60 to ship a radiator to my house. And on Amazon, I can get free shipping. So, for me, Amazon is the better choice.
 
I checked Amazon vs the link above, and moparwholesaleparts.com wanted about $60 to ship a radiator to my house. And on Amazon, I can get free shipping. So, for me, Amazon is the better choice.

In most cases (not all) Amazon is a better deal, especially if you can get the free shipping. I've noticed a lot of those dealer websites really screw you on the shipping cost.
 
In most cases (not all) Amazon is a better deal, especially if you can get the free shipping. I've noticed a lot of those dealer websites really screw you on the shipping cost.
Agreed. Unfortunately, I can't seem to find a sane instance of a Mopar water pump on Amazon. I can get one for $155 + ~$10 shipping on the other place. Haven't seen anything close on Amazon.
 
Agreed. Unfortunately, I can't seem to find a sane instance of a Mopar water pump on Amazon. I can get one for $155 + ~$10 shipping on the other place. Haven't seen anything close on Amazon.

Yeah, it's hit and miss unfortunately!
 
In most cases (not all) Amazon is a better deal, especially if you can get the free shipping. I've noticed a lot of those dealer websites really screw you on the shipping cost.
Jeep/Chrysler/Fiat or whoever else owns it does seem to charge a crap ton on shipping.

Most of my Ford parts I can get overnighted for less than $8
 
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Are you certain it's not the radiator cap that is leaking? When they age they start leaking from not being able to hold the pressure as the system runs under. A fresh radiator cap with the correct 18 lb. pressure rating would be something I'd replace before replacing the radiator.
 
Are you certain it's not the radiator cap that is leaking? When they age they start leaking from not being able to hold the pressure as the system runs under. A fresh radiator cap with the correct 18 lb. pressure rating would be something I'd replace before replacing the radiator.
I have not tried replacing the radiator cap yet. I will do that.

If that’s good, do you think I should consider deferring the rest of the overhaul (including radiator and water pump) for now?
 
I have not tried replacing the radiator cap yet. I will do that.

If that’s good, do you think I should consider deferring the rest of the overhaul (including radiator and water pump) for now?
It'd only cost a couple bucks to swap that radiator cap out, I'd have replaced it by now to see if it helps. Radiator caps do lose their ability to hold pressure and when they do they leak coolant when the engine gets hot enough.
 
It'd only cost a couple bucks to swap that radiator cap out, I'd have replaced it by now to see if it helps. Radiator caps do lose their ability to hold pressure and when they do they leak coolant when the engine gets hot enough.
Ok, new radiator cap is on. I will run it a bit and see if it helps.

Also, I bought some of the constant tension hose clamps. I ordered these 1-15/32" - 1-3/4" ones, but they only will fit on the upper radiator hose radiator side. What is the recommended sizes for the other clamps? I.e. upper radiator hose engine side, and both ends of the lower radiator hose? I know I could figure it out, but I am also pretty sure one of you guys (e.g. @Chris) knows off the top of their head.