Leaking Aluminum Radiator: Is this fixable?

[bRIBEGuy]

Well, last winter I pulled the trigger on a nice Champion 3 core aluminum radiator for my XJ after being plagued with a passenger side leak on the factory rad.  I rebuilt the whole cooling system in April this year, and the set-up has been working great.  Up until a month ago that is.................

One day I notice a large pool of coolant under the Jeep again.  ARG!!!  The engince compartment was spattered green, so I cleaned everything off, topped off the resevoir, and started watching over the next few drives.

At first I figured maybe it was the lower rad hose connection, as the coolant seems to be pooling under that spot, and then dripping down thru the frame.  Drivers side leak.  Great.   

I reseated the lower hose, adjusted the clamp, and tried again.  Still leaking.  And the hose is dry to the touch.

So now I'm assuming it's the radiator, which seems odd to me as it's only been in the Jeep for 5 months, and really hasn't seen any abuse.

I contacted Champion Radiators to see about warranty, and the process is a bit conveluded.  Basically I have to pull the rad, pack it up and pay to ship it back to them (California?).  At that point, they'll inspect it and pressure test it, and if at that point they agree that it's a manufacturing defect, then they'll approve a new radiator for me.  Which I have to pay shipping on again.  Last radiator cost $60 to ship, and took 3+ weeks to arrive.  As you can imagine, I'm note hugely thrilled with the idea of not having a radiator for over a month, and for having to shell out $120 in hopes of a warrenty replacement.

So............after much wrambling, here's my question(s):

Is a leaking aluminum radiator something that can be easily repaired locally?  Would it be more cost feasible to go this route instead?  Any recommendations on a shop that could do this sort of work?

As always, and information is appreciated.

[JackstandJohnny]

You are jumping the gun.   Find the real problem first.  Sounds like your water pump is fried.

[bRIBEGuy]

Water pump is also 5 months old.  Leaks dont seem to be anywhere near the pump.  How could the pump = leaky rad?

[JackstandJohnny]

pump goes bad, the bearing goes bad, it can lead to gushing coolant and big puddles after the motor turns off. but its not noticable when driving. just the next morning or when you get out.

[bRIBEGuy]

That sounds pretty much like the scenario..........runs fine (no overheating), and creates puddles when sitting.  Except the pump seems dry, and the coolant seems to be coming from the rad down low on the drivers side.

Oi...........I wish all mechanical problems were black & white simple!

[JackstandJohnny]

its a jeep dude. its never simple!
try and get the pump on warranty if you can.

i've had a few like this. its tough to diagnose, but its a free place to start.  grab the pulley for the waterpump, if you feel any play (or coolant comes out) might be your problem. take belt off first.

its rare for an aluminum rad to leak like that i'd imagine, unless its punctured. 

others might be able to guide you a little better cause they know XJs better than i do.. XJs don't live long when they are in my hands; they find their death quick

[BUKI]

Pressure test the system.  If the engine compartment is

 

The engince compartment was spattered green

then your probably leaking while driving and the coolant is hitting fan.  either buy a pressure tester from PA and take it back or get a shop to put it under pressure.  You would be able to find the source pretty quick, by the sounds of it.  Then you will KNOW if its the rad and can send it away with confidence or put pepper in it .

[birdo]

Any coolant dripping off the tie rods? If so, chances are it's the water pump. It is darn near impossible to crawl underneath and look upwards to see the weep hole on the water pump housing. Radiator leaks are usually a little more obvious with green coolant evident on the fins and the tanks.

[Fredduck]

For sure pressure test it.
If it's the rad, the rad shop behind Shaw GMC does aluminium
City-wide radiator

[bRIBEGuy]

Thanks for the advice guys.

Played around under the hood again last night.  Coolant is definately hitting the mechanical fan, as it's being flung up onto the bottom of the hood.  Waterpump & area beneath seems dry.  Coolant seems to be "pooling" out from under the radiator itself as best as I can tell.

Cleaned it up, brought it up to temp, and ran it at speed in the driveway to see if I could "see" any issues/leaks.  Nope.  After shutting it down though, I could see some faint steam waifting up out of the radiator fins.

Looks like I'm going to have to call around and get it pressure tested.

[.:.Dingman.:.]

For sure pressure test it.
If it's the rad, the rad shop behind Shaw GMC does aluminium
City-wide radiator

X2 just got a rad back from them and they did a great job.


Dingman

[bRIBEGuy]

Pulled the rad and took it to City Wide Radiator.  GREAT groups of people there.......thanks for the referal CJA.

Anyway, Champion 3-core aliminum radiator is leaking from both headers and is not fixable.    Pretty much sucks after only having 5 months of running.

Now I'm trying to figure out what to do.  CWR is reccomending going to a single core OEM style plastic/aluminum rad, but I'm hesitant since my 2000 XJ came with a two core from the factory.  Not convinced a single core will do it's job on a lifted XJ's with 32's and stock gearing.

Champion will do a warrenty exchange, but it will cost me $120 in shipping, and they won't have any rads in stock for a month.  Not sure I want the Jeep sitting for that long.

Advice or thoughts? 

[JackstandJohnny]

i thought those rads were bullet proof, or at least leak proof??? you must be fumed. i would be.

[binare]

Did you buy it locally? Maybe The dealer will work with you on that.

[bRIBEGuy]

i thought those rads were bullet proof, or at least leak proof??? you must be fumed. i would be.

Could be bullet proof, never thought to try shooting it.     Seems kinda tempting to try now....lol! 

Leakproof?  Certainly not. 

Fumed?  Certainly yes.

Radiator was not purchased locally, but directly from Champion Radiators in California.  Boo......

I'm toying with just dropping in a single core stocker for now to keep the Jeep rolling, and to try and work something out with Champion.  I really did like how the all aluminum rad was working, and I did notice a temp drop over my previous factory 2-core.  I'm just not sure if an OEM 1 core will be up to the task?

Really just don't want the Jeep parked for the next month plus....