so my truck started leaking coolant around the intake, and my mechanic thought it was that super fat o-ring, changed it, filled it up with coolant and it started leaking again, pulled the front cover and found the gasket was in very bad shape, as was the front covers face.

My question is can this be fixed, and how, (welding, Brazing, ect...) or do i need to get a new front cover, and where can i find one?

 

I am sure it could be repaired, they can do amazing things with metal repair these days. It would have to be filled and then machined flat again. The thing is depending on labor rates you could be looking at more to repair it than replace it.

My fear would be that whatever caused that corrosion may have done it to the inside of the housing also.

 

Do you have an early 2004?

 

Here is a link for the prices and part numbers on Parts Guy Ed's site. Probably won't find new parts cheaper.

www.partsguyed.com

 

my truck was built in may of 04,

they parts link shows the cover at $317.00 thats about what I expected, has anyone out there repaired one like this? My truck is currently still in the shop getting head studs, new oil cooler, egr delete, ect...

 

If you want to try to repair it, you could find a custom welding and machine shop and ask them for an estimate. I don't think I would trust a regular metal filler.

 

if you cant repair it... do yourself a favor get a cover for an 05, with that you need a wateroump and a lower radiator hose for an 05 truck.

 

Hey Cheezit,

Out of curiosity, what are the differences? I know the 03's and early 04's had a rash of bad water pumps that had the shafts breaking. Is an upgraded water pump the main difference?

 

yes the bigger water pump. we had / have a issue with 03/04 pumps breaking the impellers.

 

Well it turns out it could be welded up.
I called a local engine builder, Ray Fletcher at performance machine, in Lone Grove Ok.
$75 to weld it up, $40 to mill it back down flat, for a grand total of $115
It took 3 days due him being backed up, and me being a new customer.
I'm happy with the way it turned out, and I will definately use him from now on for all my machine work.

 

Good deal, glad it worled out for you.

 

I thought a May 04 built engine would already have the 100mm pump in it?

 

Hmmmmm. I think that's still an 04 motor and IIRC the bigger pumps didn't go in until the 05 motors although I saw some supposedly 05 stuff on an april 04 engine??????

 

I don't know, my books say before 9/22/03 you have a 90mm water pump and after 9/22/03 you have the 100mm water pump. I guess I'll fine out tomorrow. My water pump when out this morning and I ordered the big pump and mine is a build date Jan. 04 with ICP in the valve cover.

 

Damn.......and I was thinking (there's that dangerous word for me again) that all this time I had the small pump on my 04 motor. Maybe it's time for a gas burner