Upper Rad Hose Leak

[97' 4 Popper]

Just replaced my water pump, I havent started the Jeep yet. I just filled it with water to check for leaks and immediately water started leaking from the upper rad house at the top of the thermostat.

I have the hose right above the tab and the clamp is aligned in the same spot where is grooved into the hose.

Tension seems good on the factory clamp.

New clamp, new hose? What did I do wrong, you know, other than owning a rusted out TJ for the last 5 years.

 

[TJ4Jim]

The thermostat housings are a cast aluminum and can show signs of corrosion and pitting as they age preventing the hose from seating and sealing properly. Swapped mine out a few years ago and it was like $15 for a new one.

 

[97' 4 Popper]

The thermostat housings are a cast aluminum and can show signs of corrosion and pitting as they age preventing the hose from seating and sealing properly. Swapped mine out a few years ago and it was like $15 for a new one.

The metal didnt seem too corroded, but it had a lot of dried coolant powder/debris caked on. Possibly the rubber is deformed from that increased thickness.

 

[TJ4Jim]

The metal didnt seem too corroded, but it had a lot of dried coolant powder/debris caked on. Possibly the rubber is deformed from that increased thickness.

Possibly or a pin hole thru the casting.

 

[97' 4 Popper]

Well I decided if the hose was gonna be replaced anyways why not try to rework it. I cut the last quarter inch off the rubber hose where it was flared out. This pushed the clamp up relative to the hose and stopped the leak.

Now I have another problem, my petcock came out of the radiator along with a small o ring. Tried to push it back in and tighten but it keeps draining. I think the rest of cooling system is about to fail from neglect and age.

 

[macleanflood]

When I replaced my thermostat housing on my 97 I had a devil of a time getting it to seal. I ended up having to dress the block with a file and use a belt sander on the housing...even brand new it wasn't close to being flat.

I'd follow the section in the resources section and just replace everything including the water pump.

And if I didn't know anything about the timing chain I'd probably do that and a crank pulley, seals and gaskets.

That's a whole lot of parts canon for a leaking hose.

-Mac