Couger1968
Dazed and Confused
My intercooler filler neck has seen better days. I would like to have a new one welded on, but would like to keep it stock looking. What would I need? Any ideas, thanks
Intercooler filler neck
- Thread starter Couger1968
- Start date
![Quickstop [UK]](/data/avatars/m/5/5165.jpg?1570199786){kind=avatar}
Quickstop [UK]
Combating adversyty.
Re: Intercooler filler neck
You need the aluminum flange for our vehicles. I think a stock rad cap is about 2.5" and the stock IC is 2.25. I tried finding the smaller flange to weld on and had no luck so now I have the full size one on the IC.
Whilst this is an improvement on the 5/8 NPT allen plug, I wouldn't recommend it. In fact, if you find the smaller flange, I may consider rewelding my filler neck and repowdercoating it - I dislike it that much.
You need the aluminum flange for our vehicles. I think a stock rad cap is about 2.5" and the stock IC is 2.25. I tried finding the smaller flange to weld on and had no luck so now I have the full size one on the IC.
Whilst this is an improvement on the 5/8 NPT allen plug, I wouldn't recommend it. In fact, if you find the smaller flange, I may consider rewelding my filler neck and repowdercoating it - I dislike it that much.
Davemc1963
93 Ty Owner
Re: Intercooler filler neck
Replacing the intercooler filler neck was one of the first jobs I had to do to my Ty. It was shot and holed. It looked like it had suffered from some sort of electrolytic corrosion. The rest of the cooler was fine.
Against my better judgement, after removing the original neck, I firstly tried to aluminum 'solder' the new one using a solder kit from a vender that sells Eastwood stuff. I failed and melted it!
My second 'temporary' attempt was to thoroughly clean up the hole slightly larger than the new filler neck and bond it with JB weld. You can apply sufficient and smoove it inside the head tank , creating a good albeit originally a temporary job. After eight years, it has never looked like a temporary repair or looked likely to come apart! I got mine in the UK from here:-
http://www.thinkauto.com
Catologue Page 74, RN2 Ali radiator neck- Japanese small cap size @ £21.94.
Not cheap, but I couldn't find one (or two in my case) anywhere else at the time.
Replacing the intercooler filler neck was one of the first jobs I had to do to my Ty. It was shot and holed. It looked like it had suffered from some sort of electrolytic corrosion. The rest of the cooler was fine.
Against my better judgement, after removing the original neck, I firstly tried to aluminum 'solder' the new one using a solder kit from a vender that sells Eastwood stuff. I failed and melted it!
My second 'temporary' attempt was to thoroughly clean up the hole slightly larger than the new filler neck and bond it with JB weld. You can apply sufficient and smoove it inside the head tank , creating a good albeit originally a temporary job. After eight years, it has never looked like a temporary repair or looked likely to come apart! I got mine in the UK from here:-
http://www.thinkauto.com
Catologue Page 74, RN2 Ali radiator neck- Japanese small cap size @ £21.94.
Not cheap, but I couldn't find one (or two in my case) anywhere else at the time.
Re: Intercooler filler neck
This Mishimoto coolant neck at Summit appears to be the correct size, or very close. Says caps that fit are the small design for 02-07 Subaru WRX.
http://www.summitracing.com/parts/mio-mmfn-s/overview/
This Mishimoto coolant neck at Summit appears to be the correct size, or very close. Says caps that fit are the small design for 02-07 Subaru WRX.
http://www.summitracing.com/parts/mio-mmfn-s/overview/
Couger1968
Dazed and Confused
Re: Intercooler filler neck
Thanks. I wonder if this will fix my issue. I keep losing coolant out of my intercooler and it ends up in my over flow tank. I tried changing my cap and it didn't help. I have re-plumbed the system with 3/4 hose years ago and never seemed to have a problem before. After my rebuild it seems to be more of an issue.
Thanks. I wonder if this will fix my issue. I keep losing coolant out of my intercooler and it ends up in my over flow tank. I tried changing my cap and it didn't help. I have re-plumbed the system with 3/4 hose years ago and never seemed to have a problem before. After my rebuild it seems to be more of an issue.
Quickstop [UK]
Combating adversyty.
Re: Intercooler filler neck
I would be asking why it is overflowing and I think you need to look elsewhere. If rubber hoses, are you sure the fluid circulates? If there is a kink, and there often is down by the pump and the CAC, your fluid will boil and it will overflow.
I would be asking why it is overflowing and I think you need to look elsewhere. If rubber hoses, are you sure the fluid circulates? If there is a kink, and there often is down by the pump and the CAC, your fluid will boil and it will overflow.
Couger1968
Dazed and Confused
Re: Intercooler filler neck
I am still having trouble accessing this forum. I agree that it probably isn't just a neck problem, but mine has always been bent since I have owned it. I straightened it as much as I could ,but it is still not great. It looks as though something was dropped on it. I thought it was an air in the system problem. I actually have a length of clear hose in the system to check flow and see it is flowing well. My latest try was to reverse flow through the system. How I originally had it was upper cooler sucked out the bottom then into the top of a B&M super cooler then out the bottom it to the top of the lower exchanger.The pump then drew of the bottom of the lower and flowed to the top of the upper. Kind of like factory. The problem is, if there is any air in the system it is trying to be sucked down to the bottom of the system. I now have it draw off the bottom of the upper directly into the pump and push up through the lower into the bottom of the B&M out the top and into the top of the upper cooler. I figure any air that is in the system will naturally go up and the pump can push it out. I read a pump is more efficient pushing than it is pulling anyways. That is why a fuel pump is in the back. Maybe I am wrong. I lost coolant going both ways. I still think it might be air coming out and kind of burping and pushing it into the overflow.
I am still having trouble accessing this forum. I agree that it probably isn't just a neck problem, but mine has always been bent since I have owned it. I straightened it as much as I could ,but it is still not great. It looks as though something was dropped on it. I thought it was an air in the system problem. I actually have a length of clear hose in the system to check flow and see it is flowing well. My latest try was to reverse flow through the system. How I originally had it was upper cooler sucked out the bottom then into the top of a B&M super cooler then out the bottom it to the top of the lower exchanger.The pump then drew of the bottom of the lower and flowed to the top of the upper. Kind of like factory. The problem is, if there is any air in the system it is trying to be sucked down to the bottom of the system. I now have it draw off the bottom of the upper directly into the pump and push up through the lower into the bottom of the B&M out the top and into the top of the upper cooler. I figure any air that is in the system will naturally go up and the pump can push it out. I read a pump is more efficient pushing than it is pulling anyways. That is why a fuel pump is in the back. Maybe I am wrong. I lost coolant going both ways. I still think it might be air coming out and kind of burping and pushing it into the overflow.
Quickstop [UK]
Combating adversyty.
Re: Intercooler filler neck
It's a PITA to bleed the system, I agree but I would have thought that if it burped, it wouldn't overflow, the air would just be sitting at the top in the IC. If it's spilling out then pressure is forcing it out of the system somehow.
:2cents:
It's a PITA to bleed the system, I agree but I would have thought that if it burped, it wouldn't overflow, the air would just be sitting at the top in the IC. If it's spilling out then pressure is forcing it out of the system somehow.
:2cents:
Couger1968
Dazed and Confused
Re: Intercooler filler neck
I tried another experiment and cut a small rubber gasket out of a inner tube about the size a a quarter and placed it in the filler neck and put the cap on and drove. When I got home I found that it had built up pressure again, but no fluid loss. I left it running and took the fuse out of the pump and slowly opened the cap. Once I got it opened I put the fuse back in an the fluid rose a little then settled down. I am not sure what is actually happening. I can see how it can surge a little when the fluid starts moving, but how does it build pressure. I would think if I had a leak somewhere I would think I would lose fluid somewhere not just to the overflow tank. It must be air, but where. I have took the upper off and lifted it, even tried jacking up the truck in different corners to make sure. My clear tube still shows a bubble here and there still. My IAT temps don't look to bad so at least that is OK.
I tried another experiment and cut a small rubber gasket out of a inner tube about the size a a quarter and placed it in the filler neck and put the cap on and drove. When I got home I found that it had built up pressure again, but no fluid loss. I left it running and took the fuse out of the pump and slowly opened the cap. Once I got it opened I put the fuse back in an the fluid rose a little then settled down. I am not sure what is actually happening. I can see how it can surge a little when the fluid starts moving, but how does it build pressure. I would think if I had a leak somewhere I would think I would lose fluid somewhere not just to the overflow tank. It must be air, but where. I have took the upper off and lifted it, even tried jacking up the truck in different corners to make sure. My clear tube still shows a bubble here and there still. My IAT temps don't look to bad so at least that is OK.
Quickstop [UK]
Combating adversyty.
Re: Intercooler filler neck
Are you still getting into boost? Maybe your upper IC has a leak. Can you pressurise the IC and see if you get any bubbles?
Are you still getting into boost? Maybe your upper IC has a leak. Can you pressurise the IC and see if you get any bubbles?
Couger1968
Dazed and Confused
Re: Intercooler filler neck
I kind of was wondering the same thing. I think I will put the old inner tube on the intercooler and try pressurizing it and see what happens
I kind of was wondering the same thing. I think I will put the old inner tube on the intercooler and try pressurizing it and see what happens
Couger1968
Dazed and Confused
Re: Intercooler filler neck
Well I did a pressure test in the upper and I did see bubbles coming out at pressure. It must be small because I don't lose fluid otherwise. I looks like I am getting a new intercooler.
Well I did a pressure test in the upper and I did see bubbles coming out at pressure. It must be small because I don't lose fluid otherwise. I looks like I am getting a new intercooler.
cloneman315
Active member
Re: Intercooler filler neck
fill the system from the bottom like you do on marine motor outdrives. Will push the air out.
fill the system from the bottom like you do on marine motor outdrives. Will push the air out.
Couger1968
Dazed and Confused
Re: Intercooler filler neck
That is how I did fill it, but the upper has a leak and pressurizes the cooler and forces the coolant out.
That is how I did fill it, but the upper has a leak and pressurizes the cooler and forces the coolant out.
Couger1968
Dazed and Confused
Re: Intercooler filler neck
This was the neck I was considering.
http://www.amazon.com/gp/product/B0...38RX29ZXQU8Y5&psc=1&ref_=wl_it_dp_o_pC_nS_ttl
This was the neck I was considering.
http://www.amazon.com/gp/product/B0...38RX29ZXQU8Y5&psc=1&ref_=wl_it_dp_o_pC_nS_ttl
Quickstop [UK]
Combating adversyty.
Re: Intercooler filler neck
Sorry to hear that but at least we know the problem. In the UK, there is a substance called Rad Weld which you can put into radiators and it seals them up on contact with air. Maybe there is an equivalent in the US though I feel it is more of a bandaid than a permanent fix. Up to you but just an idea.
:tup:
Sorry to hear that but at least we know the problem. In the UK, there is a substance called Rad Weld which you can put into radiators and it seals them up on contact with air. Maybe there is an equivalent in the US though I feel it is more of a bandaid than a permanent fix. Up to you but just an idea.
:tup:
Couger1968
Dazed and Confused
Re: Intercooler filler neck
I was kind of thinking of the same thing, but like you said it's kind of a bandaid. I am not sure it would work well since there isn't much heat and pressure. Most of the time it's trying to push air into the coolant. Where a radiator the coolant is trying to be pushed out.
I was kind of thinking of the same thing, but like you said it's kind of a bandaid. I am not sure it would work well since there isn't much heat and pressure. Most of the time it's trying to push air into the coolant. Where a radiator the coolant is trying to be pushed out.