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https://en.wikipedia.org/wiki/Casting_defect#Gas_porosityhttps://www.dynacast.com/porosity
I recently went through the same problem of a leaking bottom intake plate. Went through two gaskets with no success. finally got it by scrubbing both matting surfaces with steel wool, to a shiny finish. Cleaning it up with carb cleaner then using AISIN FIPG.
Here's a pic from my project today. Shifters locked in Reverse and Low range, no way to get it out of gear. Cut and welded a link of chain on the shifter. Huge padlock. Just made to slow a thief down. Sent from my PH-1 using Tapatalk
No torque just what feels good by hand.
As you said, we can only hope to slow thieves down. That said, I will be copying this system because I'm guessing fewer thieves will want to make a horrendous racket with an angle grinder for a minute to cut that padlock off.I would also suggest some kind of system that disables the ignition or starter motor. Preferably both because you could still back the truck onto a trailer in 4wd low.
Gotcha. Did you end up using the gasket WITH the FIPG? Sent from my PH-1 using Tapatalk
No gasket. Just a thin layer on plate and intake, let it sit for 5 or so minutes then bolt up
Gotcha. I'll have to try this. Thanks for the heads up. Is this on a stock intake? Sent from my PH-1 using Tapatalk
Yes stock intake and plate. Hope your next try works. If not it will suck, but you can try pulling the intake off and getting a big sheet of 120 or so grit sand paper and sand it on a table.
Can you come up with some sort of do-hickey to pressurize the cooling system without the engine running?Then pressurize the system and look and SEE where it's leaking.....
Aisin FIPG may work. I’ve never used it. If I were to use it, I would use it with the gasket.I have not seen what Aisin FIPG looks like. I have used and seen what Permatex’s thread sealer looks like.Here’s the tech spec on: https://www.permatex.com/products/thread-compounds/thread-sealants/permatex-high-performance-thread-sealant/and why I would try it:https://441py33rout1ptjxn2lupv31-wpengine.netdna-ssl.com/wp-content/uploads/tech_docs/tds/56521.pdfLet us know whatever you do and how it works. You’re just kidding about selling you truck, aren’t you? Gnarls.
I'm just wondering if the leak is somewhere else and it only looks like it's coming from the plate.
This is kind of butch but I think it will work for you. Drop in some good radiator/cooling system sealant and I bet the leak will stop. K Seal or Alumaseal both work great. This is typically a permanent fix too until you tear it apart.
I've been told those can plug up radiators and heater cores. I've seen it happen once, which is hardly a huge sample size. But it's enough that the idea of using those gives me pause.
In re selling, I think I will share my experience:My truck spent one summer (my busy season when I most need it) constantly letting me down: A huge exhaust leak that I battled for ever, Overheating issues that (I think) ended up killing the ignitor, oil loss that would put the Exxon Valdeez to shame, and constant battles with the atrocious neglect and shoddy maintainance by previous owners. After the ignitor went out I decided to sell it.Long story short: It turned out that it was less trouble and expense for me to stick with a vehicle that had known problems, even several major ones, than to take on a new vehicle with a whole new batch of unknown problems. If I were you I'd let the truck be for a couple weeks while puzzling on it. A solution might just come to you at 3 AM one day. Speaking of which, are the mating surfaces flat? Is the plate bent? What happens if you turn the plate front-to-back and try again? Does the leak go away? Does it move? Is there a blockage in the coolant passage that puts undue pressure on your sealing job? Can you drill and tap some extra bolt holes to squish the plate against the intake where it's leaking?Can you go back to the old intake manifold? I know the two-piece adapter is not well liked, but could you weld the two pieces together? Do you have any machinist buddies who could make a one-piece adapter for a reasonable cost? Do you want to buy a milling machine and make one yourself? (Okay, buying a $1200 milling machine to fix a coolant leak is overkill, but at least you have the milling machine afterwards!)These are just a few ideas and suggestions. At the risk of sounding like Gnarly, they may be worthless
Everyone's experience is different.I've used Alumaseal powder several times and it works, AND it DID NOT plug up anything.I've used it and seen it work on 3 of my 22REs!I was going to recommend that option if the Permatex Thread Sealer did not work - which I believe it will. I'd really like to understand if the mating surfaces are FLAT?Gnarls.
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