Radiator Side Tank Gasket Leak Repair

NOTE: Radiator side tank gasket leaks can easily be mistaken for tank or header leaks. If a plastic tank leaks from the header joint gasket, tighten the clinch tabs using Radiator Core Remover/Installer or locking-type pliers. If the tank still leaks. remove and repair it.





1. Pry open clinch tabs except those under inlet, outlet and radiator neck, using Radiator Core Remover/Installer or screwdriver.
^ Lift tabs only enough to allow removal.





CAUTION: Do not over bend tabs. Over bending tabs could result in breaking tab. If more than three tabs are broken on one side of header or more than two adjacent tabs are broken, the core must be replaced.

2. Lift tank and slide it out from under remaining clinched tab.
^ Tapping tank with your hand may be required to dislodge gasket.
3. Lift remaining tab(s) with pliers.
4. Remove and discard gasket. Clean header gasket groove of dirt and old rubber and sealing edge of plastic tank. Inspect header gasket surface and tank flange for evidence of leaks and surfaces and remove dirt, burrs and bumps.
5. Remove transmission oil cooler, if equipped, and install it into new tank.
6. Dip or coat new gasket in engine coolant and position it on header surface.
7. Position tank and gasket to header. Clamp it in place and secure it by bending four clinch tabs.





8. Clamp remaining clinch tabs around header using Radiator Core Remover/Installer or pliers.
^ Start at center and work towards end.
9. Replace core if there are more than three tabs broken on one side or if two adjacent tabs are broken.
10. Install radiator drain cock, if removed.
11. Test radiator for leaks.