Engine/Transmission (1994 - 1998) COOLANT LEAK---thermostat area!!!

[TSPowell]

OK, I've had this leak for about a year and half. I stopped driving the 95 after I bought my 04. 5, the 95 had this bad coolant leak before I parked it. 2 months ago I started driving the 95 to save some "around-town" miles on my new truck. But the leak is getting worse. I would say 1 gallon for every 1000 miles, maybe a little less. Its right around the front passenger side of the engine. I have read a few post that sound similar. I've changed ALL of the gaskets associated with the thermostat and cleaned every part before reassembly. Several times I have washed the engine off in hopes to pin-point the leak, but have had no success. I have come to a couple of conclusions, starting the the less expensive.

1. There is a little coolant line by the thermostat, changed that and tightened the fitting going into the therm-housing-no fix.

2. thermostat and gaskets-no fix.

3. The little freeze plug located on top of the head between injectors #1 and #2, have not changed this.

4. Changed gaskets and cleaned parts surrounding the oil cooler-no fix

5. Head gasket, don't really want to change this, would rather spend money on my 04. 5.

Im guessing its probably #5. So if this is what I resort to doing, what is the expected cost to replace the gasket. Any good mechanics around the Denver, Fort Collins CO area. I refuse to take it to the dealership, Im not stupid!

Any help would be great!

 

[Joe G.]

My '95 did that. It was the water pump.

 

[TSPowell]

Ive checked the water pump and nothing leaking around that area. Its all from the thermostat back, on top of the head and down to the oil cooler area. I would post a pic, but the site says its too big.

 

[JClayton]

Check around the head bolt that goes down right beside ot the thermostat housing. Alot of times theblocks develop hairline cracks between the bolt holes and the water jackets and will leak. All you have to do ispull the bolt, thread seal it very well and reinstall. Mine did that with my studs and after sealing it, have no more problems.

 

[hsmith]

Headgasket most likely. Did mine at 150k and another last week at 225k.

 

[flyairam]

It's the head gasket. Been there, done that with my '94. It won't be cracked, just leaking. Cummins has an improved part number and, depending on your power level, you might consider going to a thicker one.



I repaired mine by 'self and regretted it a out halfway through. It's a big one-man job - even using a cherry picker to hoist the head.



You'll probably want to leave the turbo and exhaust manifold mounted or you'll never get the manifold back on because of shrinkage.



Good luck.



Randy