D4 7u Runs again, but....

Hi

there is an anti rattle/pull back spring in the bellhousing that connect bettwen the bellhousing casting and the clutch assembly that can get lost or break. Maybe check to see this is in place first. Otherwise I would suspect something is loose in the over centre latches or perhaps the drive shaft coupling is incorrectly fitted or loose.

WRT to the head leaks, I think you are probably looking at a partial head gasket failure or most likely leaking water directors due to the directors either being missing, split or not seated correctly on install. Maybe it will take up with time.

Use some stop leak I am using one called Dike these days. I like it over BarsLeaks. I think it is less likely to clog a partially plugged radiator than BarsLeaks.

Did he check the liner protrusion?

He did a lot of work on liner protrusion. He clamped the liners down and made sure the protrusion was with in spec (0.004 I think), consistent between all the liners, and very consistent around the circumference of every liner.

I would not tear a newly repaired engine back down for a leak like that unless it won't stop with a cooling system stop leak product. Even if you have to go in and unclog the radiator later, that is less of a job on most machines than removing the head yet again.

It sounds as if there may be something unusual about this one since it was leaking in that area before the tear down and is leaking in the same spot after a proper repair. I'm wondering if perhaps the block casting is porous or cracked between the water jacket and the tapped hole the studs screw into. Of course could also be the head cracked in the area of the two studs where the coolant is leaking. Not like it would be easy to see that one unless you pressure checked the head.

He ran it a couple of times yesterday then removed the offending stud and watched it for a while. Of course it didn't leak right away. When he came back a half hour later he could see a wet spot on the side of the clearance hole in the head. We are pretty sure the casting is porus and seeping. The entire cooling system was full of rusty crud when he took it apart. I think the cat came from a farm in southern California originally pulling a disc, the hour meter stopped just shy of 10,000 so no idea how many hours are actually on it. It looked like the cooling system was run on water for a long time without antifreeze.

To repair this he added some sodium silicate to the cooling system, also known as water glass. This should work its way into any cracks or holes then dry up hard when exposed to air. This way we don't fill the cooling system with contaminates. We will know in a couple of days.