Coolant Return Hose Flange Leak--AGAIN!

Get a load of this. Back in August, I took the car in for a repair of a coolant leak that turned out to be problem with the return hose flange (the thingy where the thermostat is located). Thanks to all of your help last time. http://forums.tdiclub.com/NonCGI/ultimatebb.php?ubb=get_topic;f=3;t=008413#000003

Well, I again have a coolant leak in the exact same location!

Does anyone know of a Technical Service Bulletin on this issue? Is there a replacement part that permanently fixes the problem?

Thanks,
-BIODEZL

makes me wonder if you dont have a blown headgasket or some other problem that is causing high pressure in the coolant system????

or not... maybe just a bur or chip or something minor.... Bill

If the plastic water necks get overtorqued, they will leak.

And the overtorquing could lead to warping/deformation of its mating surface. Replacing the o-ring will not be enough. The entire piece should be replaced.

BTW, that's the water inlet, not a return outlet.

[ November 13, 2002, 06:23: Message edited by: MOGolf ]

Thanks for the clarification on the purpose of the part. I will share your collective experience re: the problem of over-torquing (sp?) and the need to replace the whole part with the stealer next Monday. The stealer previously claimed to replace the whole part...we'll see. God forbid it is a head gasket.

The last time the car was in for repair, they also identified that the transmission fluid was "dark." Could this be a related problem?

-BIODEZL

the transmission fluid should be replaced every 60-80,000 miles with Redline MTL.

As for the head gasket theory, dont let that get you worried. I dont think there is one documented case of head gasket failure on your car anywhere on the forums. it just doesnt fail, its a solid slab of metal.

There is no TSB on your problem. this is the first time ive ever seen or heard of this part leaking. I would believe its a problem with whoever is installing it. Take it to a good independent if your out of warranty. There is no reason to use a dealer for this little stuff. The independant (if good) will probably do a better job than some flat rater at the dealer who only wants to get your car out of the bay.