Lost the radiator at 31,000-assembly problem or design flaw?

[J_Melton]

Dear Fellow TDRs:

I have a research assignment for you. While on vacation towing the fiver I pulled into Torrey, Utah and discovered a coolant leak. Found a local mechanic that looked it over. I had a hole in the radiator!

Since it was still under warranty I called DC's Customer number. First person I talked with was very unhelpful. Told me to call roadside assistance and have it towed to Richfield, Utah 65 miles away. She didn't care that I had a stranded fiver, family and pets. Second call got disconnected. On the third call I reached a helpful person who seemed to understand the problem and told me I could have a local repair rather than tow both to Richfield. He gave me a file number and instructions for reimbursement. Hope this doesn't turn into major brain damage.

Here is what the mechanic found. There is a protuberance at the bottom of the radiator shroud where the fan clutch actuator goes up to the fan hub. It seems that on my truck the protuberance was actually in contact with the radiator. After 31,000 miles, it had rubbed a hole in the radiator! In the attached photographs you can actually see the groove in the shroud where it rubbed the hole and was about to rub a second. Also attached is a photograph of the radiator. Just happened to have the digital along to shoot wildflowers in Death Valley!

New radiator from Salt Lake... $500+. Total replacement $778.78 including freight, labor, coolant and tax!

To make sure the problem didn't reoccur we shaved back a bit of the lip on the shroud to get 3/16" clearance between shroud and radiator.

If you've got a 2003, go check to see if you currently have adequate clearance. If yours is too close for comfort please let me know. I might need the ammunition if DC decides to play hardball on the reimbursement. Besides, it could save you a breakdown not to mention lots of $.

And yes, the wildflowers in Death Valley were worth the trip even if DC doesn’t pay for the radiator!

jack