Radiator Tank Keeps Cracking

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LoneWolf3574

Senior Member
Military
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Location
Arizona
Ram Year
2006
Engine
Hemi 5.7
About 2 years ago I replaced my radiator due to a small crack that had formed at the upper hose connection. At that time I noticed that the bolthole near the centerline of the upper core support didn't line up and the lower foot was about 1/4" (give or take) to the right of where the old radiator sat. Since then, I have already replaced the "new" radiator with another as it appears the stress caused a crack to form on the tank and have recently started having the same thing happen again.

Before I get asked, yes, I reused the old isolators because they were soft enough to compress enough to allow me to get the bolt in the hole, the new isolators were just too hard.

Any ideas on how to fix this issue? Obviously, I'm going to have to replace the radiator and I don't want to go through this every year. And no, I can't afford to or justify upgrading to a full aluminum radiator at $500 to $600.

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JimmyJimJims

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2003
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3.7L V6
I had a very similar thing happen to my 03 Ram, the tank cracked in that same spot and the isolators literally went missing (as in the bolt backed out and they flew off somewhere). What I did was install a larger washer that covers the entire diameter of the isolator to prevent so much flex and wobble. I also installed a longer bolt so the new rubber stops would compress and the bolt wouldn't magically go missing
 

Daw14

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Open up the holes some more ,oval them ,something to relieve the pressure.
 
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LoneWolf3574

LoneWolf3574

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Open up the holes some more ,oval them ,something to relieve the pressure.
Yeah, that's what I'm thinking of doing. I'd rather not, but it seems to be the most viable option.
 
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