All -

I am on my third OEM ford coolant reservoir.

• OEM tank - 205k with no leaks, overhauled rest of coolant system so decided to replace as preventive MX - big mistake :icon_rolleyes::icon_rolleyes::icon_rolleyes:
  
• 1st replacement tank - leaked at seams at 5k miles, installed with new motorcraft cap
  
  
  
  
• 2nd replacement tank - leaked at seams at 10 miles (build date March 2017)
  
  
  
  
• 3rd replacement tank - leaked at seams at 20 miles, (build date 7/20/17) - installed with another new motorcraft cap to be sure
  
  
  
  

Some googling reveals a few guys out there have tried 5 or 6 tanks until they found one that sealed. All of my replacements have had visibly poor mold lines and obvious low quality manufacturing. Visible gaps in the seams in multiple places, etc.

Dealer is playing nice with warranty exchanges, but i dont have time to drain and refill my coolant every 20 miles.

Aftermarket tanks are sticker shock at $400+.

General motor condition - 211k, runs great, preventive coolant flush/change at 205k to rotella ultra ELC, navistar pump, motorcraft tstat, ford hoses, ford radiator (small pinhole in original), ford tank, motorcraft cap. Runs correct temp, no smoke, steady coolant level (other than what leaks out of the seams).

Any ideas, recommendations, solutions? Keep plugging away until i find a good tank, or bite the bullet and go aluminum?

 

As you've discovered, you should have left well enough alone. Even Ford sells what should be considered aftermarket parts once production has stopped.

If it were me, I'd get set up to vacuum the fluid out of the tank and keep going the warranty route. Dump the recovered fluid back in the reservoir and save the flush or buying new coolant (except for what leaked out)

You can also give up on the replacements and get some fiberglass mesh and resin, sand to rough up the current tank, and seal the entire seam yourself. I had to do that on a farm tractor where the plastic reservoir kept leaking.

 

I know some Dorman items can be "hit or miss". But after replacing a couple of Ford degas bottles for stress cracks right above the seam, I decided to try a Dorman one. It came with a new pressure cap, but had fitment issues with binding threads. I purchased a new Motorcraft replacement cap and it fit much better. Knock on wood, I hadn't had any more leak issues.

 

I bought a bottle from Clay, he warranted it 2 month later. So I bought a Plastic Welding Kit from Walmart, before I even installed the new one I welded the ENTIRE SEAM! Going on 7 months without issue.

Keep in mind the Dorman bottles have issues with the cap sealing.

 

First off... I wouldn't fill to the line - that thing is inaccurate. I let the coolant settle where it wants, and it works out fine. I see in your second picture that the fluid came from above... like maybe the cap. Over-filling might have put that fluid there... or not.

I bought mine from Clay a few years back with no issues.

 

I bought one from RiffRaff as well 2+ years ago, been good ever since (knock on wood). I only replaced the original because it looked old and the inlet spout was broken by the previous owner or mechanic.

 

I bought a Dorman one a few years ago from RockAuto. No issues.

 

"After market tank are like $400" In looking just now on oreilly and a replace tank is only like 50 bucks.. that must be a mistype on the price. you were going to say $40 i guess.

 

Unless he was talking about the stainless steel tank offered by some shops.

7.3L Power Stroke Aluminum Coolant Reservoir

Cool part, but way too expensive for my blood.

 

Ohhh. Pretty ... dang useless. Where's the sight tube? Kind of the point of clear plastic.

 

I thought it was just me. I replaced the original bottle a couple years ago because it was cracked above the seam. A couple months ago I noticed the replacement was leaking at the seam. Clay sent me another one under warranty and I noticed the other day that this one is leaking too and I just put it on a few weeks ago.

The link says it has a window for coolant level monitoring.

It's also out of stock... but $400 isn't bad for what it is, I just don't think I'd pay that.

 

WOW that is nice for sure.. but like sarge said Too expensive for my blood.. getting one at o'reilly and when a problem comes up taking it back for a new one.. not all that bad.

 

Bought a Dorman also 2 years back while in Florida. Started leaking on the trip down. Was 70 bucks & change. Been good ever since.

 

I've installed a bunch of Dorman degas bottles. None have failed that I'm aware of. But easy exchange at local autoparts if you need it.

 

Replaced mine about 3 years ago and no problems. I have also learned from towing heavy to keep the coolant below the "Add" line to or else it spits coolant out like a 6.0(just a few drops not a waterfall)! Lol