Suggestions on cracked oil cooler cover

[pitpawten]

My old oil cooler cover had developed several holes in it which I had tried to patch with JB Weld previously, but never held well without leaking.

It looks like corrosion possibly from bad pH coolant or just years of erosion action - I dunno.



I had talked to tnj Murray and they had a take off but when I asked them to inspect the corners on the inside they said there was corrosion and almost a similar hole formed : /

I ordered one from eBay and got it yesterday to find this on the inside



And the corresponding spot on the outside



This looks like something smacked into it at some point.

My questions:

1. I haven't read of anybody else with this part failing but this makes three for me that have had issues am I just a magnet?
2. Do I bother taking this one to somebody who can TIG it back together or try finding another one?

 

[87cr250r]

JB Weld can work. You didn't clean it well enough. Repair it from the inside. Gouge our the crack just like you would if you were welding it.

 

[pitpawten]

JB Weld can work. You didn't clean it well enough. Repair it from the inside. Gouge our the crack just like you would if you were welding it.

Yeah my initial thought was that it should do the trick but my poor results before put me off a bit.

Got a recommendation on a local Fab shop I might see if they can knock it out as a walk-in else I might dip my toe back into the JB weld.

The irony is that I've got a nice big TIG machine with AC/DC pulse etc but haven't spent any time on aluminum so can't even use it : /

 

[87cr250r]

If you do weld it, the first pass is going to look like garbage. It floats all of the gunk to the surface. Grind it down and run another pass and all will be good.

If yo go the epoxy route you need to be able to wash the part. Caustic degreasers can be rinsed off with water. Once it's clean, grind or sand all areas you want the epoxy to adhere to bright shiny metal. Apply the epoxy as quickly as you can after exposing the shiny metal.

Be aware, epoxies exposed to water typically have lower temperature limits (usually 120°F when exposed to water) so check that product data sheet.

Belzona 1111 is the bee's knees if you can get your hands on it.

 

[ToddJK]

Just curious, but could you use white solder on it?

 

[87cr250r]

I think you would have a hard time getting the material clean enough to use those aluminum brazing rods.

 

[pitpawten]

So the TM calls for testing the oil cooler itself (slight topic change from the cover) to 150 psi.



This seems like overkill given that the oil pressure is never above (or near) 100 psi. I feel like testing it to 150 psi risks damaging am old and hard to obtain part unnecessarily.

My thought is to test to 75 psi or roughly 20% over normal operating pressure (assuming 60 for normal).

 

[rustystud]

So the TM calls for testing the oil cooler itself (slight topic change from the cover) to 150 psi.

View attachment 900032

This seems like overkill given that the oil pressure is never above (or near) 100 psi. I feel like testing it to 150 psi risks damaging am old and hard to obtain part unnecessarily.

My thought is to test to 75 psi or roughly 20% over normal operating pressure (assuming 60 for normal).

Your oil pressure starts at 100 to 120 PSI then is lowered by a pressure regulator. You can have that same pressure in the oil cooler if there is a problem with the regulator.
I have two oil pressure gauges on my dash so I can monitor my engines performance at all times. One is on the high pressure side, the other on the low side. If I get a spike in the low side I know something is up. My truck on start-up reaches 120 PSI on the high side, then slowly rests at around 90 to 100 PSI.
So test your cooler like the TM says.

 

[pitpawten]

Your oil pressure starts at 100 to 120 PSI then is lowered by a pressure regulator. You can have that same pressure in the oil cooler if there is a problem with the regulator.
I have two oil pressure gauges on my dash so I can monitor my engines performance at all times. One is on the high pressure side, the other on the low side. If I get a spike in the low side I know something is up. My truck on start-up reaches 120 PSI on the high side, then slowly rests at around 90 to 100 PSI.
So test your cooler like the TM says.

Great info here and proving again to trust the TM (and those guys with more experience)

 

[patracy]

IMHO I'd just keep looking and find a suitable replacement. I might have one actually.

 

[pitpawten]

IMHO I'd just keep looking and find a suitable replacement. I might have one actually.

@patracy that's my preference but the only other ones available that I know of (2x) are also in used and similar unknown state for $300 plus.

If you have a known good one that you're willing to part with and could get to Maryland 21617 by the end of this week, I'd love to get you some money for it.

 

[patracy]

I have a parts engine outside, when I get done with work I'll go look at it. I believe the cover is still there.

 

[patracy]

Don't know the internal shape of it, but it looks good externally.

Sent from my SM-G965U using Tapatalk

 

[pitpawten]

Don't know the internal shape of it, but it looks good externally. View attachment 900067

Sent from my SM-G965U using Tapatalk

That looks like it and given the fact that the paint isn't peeling on the outside makes me think that coolant was not leaking through.

If you think you can get that here by the end of the week let me know what I need to do, I super appreciate your quick responses as I'm hustling before the 4th

 

[DaneGer21]

Send it my way, I’ll weld it up for ya…free

 

[patracy]

That looks like it and given the fact that the paint isn't peeling on the outside makes me think that coolant was not leaking through.

If you think you can get that here by the end of the week let me know what I need to do, I super appreciate your quick responses as I'm hustling before the 4th

I will pull it off now. Send me a message with your info. I've got to go into the office tomorrow. But I can drop it off at a drop location sometime during the day tomorrow.

 

[patracy]

Just pulled it off, looks good, even had coolant in it. I've got it boxed up too. Sent you a message.

 

[pitpawten]

Just pulled it off, looks good, even had coolant in it. I've got it boxed up too. Sent you a message.

Replied to you directly with the info and this is why I love this community and the individuals in it thank you for the quick assistance!

My heart sank when I looked at the one I got off eBay and realized it was not going to be usable

 

[rustystud]

Well here's hoping you get the truck running for the Fourth !
Good luck.

 

[ToddJK]

There's usually someone here on the site that has that one part you need and definitely can be a life saver.