Rubber nipple on intake keeps blowing off

Tiny
MBULLION
  • MEMBER
  • 2002 MERCURY MOUNTAINEER
  • 128,000 MILES
Hello,

I have had the same problem probably three times. Basically what happens is there's a rubber nipple on the intake right near the firewall and it keeps blowing off resulting in loss of coolant completely (broken down and had to be towed). I had the newly designed intake put in about three months ago (the one that's metal up front near the thermostat). I was driving from Detroit to Peoria, Illinois and all of a sudden the car starts smoking under the hood. Got it towed to the nearest auto shop. And I think this is where the problem kind of started. The rubber nipple was dry rotted. So the mechanic replaced it, tightened it down, filled my coolant, and off I went(this was 2 months ago). BUT. Just yesterday, I stepped on the gas and heard a pop under the hood. And I knew it was that rubber nipple. Same thing happened. Anti freeze everywhere. Got it towed to my mechanic who is amazing. He looked at the intake and said the person who replaced that nipple used some sort of prying device. Probly a flat head screwdriver just to get it on there and take my money. My mechanic pointed out exactly what had happened and the picture probably speaks for itself. Does that look like someone pried in there because it's metal and it's torn down the middle which is why it probably gave way and blew. Under normal circumstances, would that kind of crack happen? I would think it would stay round and the cap would just blow? I'm just afraid it's going to happen again. Hopefully not
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Saturday, August 3rd, 2013 AT 6:17 PM

9 Replies

Tiny
KHLOW2008
  • EXPERT
The image did not show up correctly when enlarged and from what I see in the small picture, the part is dfinitely damaged due to external factors.

If the stopper is correctly installed, it should not give way even when the rubber itself rots as with the original. Hopefully you have not damaged the engine due to overheating.

For stoppers if you were to make it last longer, use an internal stopper ( I fabricate my own) coated with sealant and use the outer stopper to cover it up.
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Saturday, August 3rd, 2013 AT 11:35 PM
Tiny
MBULLION
  • MEMBER
How do you make/buy/an internal stopper to be covered up by the rubber stopper to provide extra protection?

I just worry that this same situation will happen again.I don't think it will (fingers crossed). But that one spot where that cap is can make the difference between operating normally or costing me another 450 bucks.

Thoughts?
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Sunday, August 4th, 2013 AT 12:02 AM
Tiny
KHLOW2008
  • EXPERT
Internal stoppers are not available. I fabricate them from wooden broom stick handle which is grounded to almost size of the tube and lightly hammered into it.

Such things should not have occured in the first place if the stopper deterioration was noticed in the first place. While removing the bad stopper, it should have been cut off using a sharp blade rather than using a screw driver to pry it off causing damage to the tube.
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Sunday, August 4th, 2013 AT 12:37 AM
Tiny
SATURNTECH9
  • EXPERT
Looks like the nipple was crushed and split on the end of it maybe from some pliers. Not something cased by it being blown off.I would also check and make sure there are no exhaust gasses causing too much pressure to cause the nipple to blow off. You rent a chemical block tester from auto zone to check that.I would straighten the end with a punch or maybe a extension. To plug it off get some heater hose and some good quality hose clamps. Clamp one end of the hose on the nipple. The for the other end of the nipple get a hose plug that fits in the hose and clamp it tightly on the other end of the hose. That will be much stronger then those cheap hose nipple caps that rot and fail.
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Sunday, August 4th, 2013 AT 7:39 AM
Tiny
SATURNTECH9
  • EXPERT
Sorry khlow2008 mike sent me a email to help with this one last night.I went into the question fell asleep woke up this morning and answered it. Didn't see your reply till I posted my answer.I have some additional info in there so that will be helpful.
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Sunday, August 4th, 2013 AT 7:42 AM
Tiny
MBULLION
  • MEMBER
Everything now is brand new on it. New nipple, new clamp, new intake. Still weary that it's going to happen again.I will def look into the chemical block tester to check the pressure.
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Sunday, August 4th, 2013 AT 10:36 AM
Tiny
SATURNTECH9
  • EXPERT
The chemical changes color to tell you there is exhaust gases in the cooling system that if bad enough can cause excessive pressure in the cooling system. Keep us posted what you find.
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Sunday, August 4th, 2013 AT 2:56 PM
Tiny
MBULLION
  • MEMBER
Is it an actual chemical I can buy or is it a unit I have to rent?
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Sunday, August 4th, 2013 AT 3:11 PM
Tiny
SATURNTECH9
  • EXPERT
You rent the tool and buy the chemical which is about 8 auto zone rents them.
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Sunday, August 4th, 2013 AT 3:34 PM

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