Bill and Greg -

Thanks for your fast replies.

The water is coming from the joint between the two halves of the heater case, near the back where the hoses are attached - but that could be because that end of the case is lower than the front.

I felt the hoses where they attach to the pipes. They feel dry. And the back of the case at the holes for the hoses feels dry too. The hoses do not go inside the case, but they do butt up pretty close to it. So water could trail along the pipes and fall inside the case if there is a leak between the hose and the pipe. I can't see how the Ranco valve could be causing the problem. The hoses leading to it are dry on the outside.

My 235 has a 4-lb cap. That's why I used lung pressure and balloon pressure to test the core. Still reluctant to puff in too much pressure. The leak today occured with only the pressure of gravity. If I don't find a leak, then I may be forced to pump in 6-10 pounds of pressure.

When I did my lung test of the core, I used two pieces of heater hose clamped to the pipes with the flat spring clamps that I used when I installed the heater. They hold tight to the pipes. I had used gear clamps before. I was leary of crushing the pipes again. So the leak has occurred with both types of clamps.

I cut off an inch of the heater hose at the core in case the insided was deformed while the pipes were out-of-round. I'll remove the hoses to the heater tomorrow and inspect them. I'll buy new ones to be safe.

I don't see any tracks of Prestone on fins in the core. Seems like it would be stained if the leak was in the passages. The cooling system is perfectly clear - no rust. So there probably wouldn't be a rust trail if the passages are leaking.

I'll attach the core to the back of the case tomorrow and leave the front open. Then I'll do my lung pressure test again while it is out of the truck. Next I'll put on the front and test again. Maybe the case is flexing the core. Also, I wonder if the core is being flexed when I bolt the case to the inner cowl??

My gut tells me that the problem is a deformed hose, or a stress crack where the pipes attach to the core. It has to be significant based on the size of the trickle of water that was leaking out.

Keep me in mind. I'll give you an update when I know more.

- Lonnie

- Lonnie
My '54 3104
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