I need help with the drain on the radiator, since my last drain and refill I have a slow drip
from the valve when its closed, the leak seams to be coming from around the hex plug
that you open and close. I have tried opening and closing it a little but it still leaks a drop
about every 10 seconds. The leak is coming from between the boss and plug, nothing
appears to be cracked or broken. Can the plug be completely removed (without breaking
something) so I can clean and inspect the boss and plug..

Any help is appreciated, Thanks to all...

_________________
Life's to short not to have fun !!!!

I don't believe it is supposed to be removable but somehow I had one come all the way out and it was very difficult getting it threaded back on while radiator is on the vehicle. If i remember had to put pressure inward while turning. It may just have to line up some groves etc to be able to pull all the way out. I may have one as a spare that I could look at in next few days.

_________________
05 Blu LIM, OME GDE Tbo, wk II 245/75/17, KC Lights, bull bar, 195K H TC
05 Blu Lim, Dayton, GDE HT, 255/75/18 , 210K , H TC
06 Bla Lim, GDE Eco, Destination AT 245/75/17, 151K, H TC
06 D Khaki Lim 126K wkII Eur TC
05 D khaki Lim 145k refurbishing
All CRDS: Fumoto, Lift , Fan Shroud mod, fuel head Gen II, SAMCOS,self TB, 2 Mic filt, Hayden

I have an old rad in the scrap pile, I can check the drain and see. May be a few days till I can get to it though.

_________________
2005 Liberty CRD. New rockers, exhaust valves; Provent, EGR block & butterfly delete & V6 air box at 100K

1998 XJ 4.0L, 2" lift

First Jeep: 1962 Willys CJ-3B

TKB4 and krb if you can look I would appreciate it, I don't want to mess this one up any more than it is.
If you could post some pic's of what you see it would be really beneficial.

thanks again, the people here are the best.

_________________
Life's to short not to have fun !!!!

I was afraid someone would have trouble with this.

I despise the design of both the radiator drain plug and the cooling system bleeder valve, located on the same side of the radiator at the top. They appear to be designed somewhat like a Dzus fastener, where a plug has a path carved into the shaft that a pin of some kind follows.

https://www.aircraftspruce.ca/catalog/h ... teners.php

https://www.baysideperformance.ca/woodc ... stener-kit

If you are ham-fisted with the drain plug or the bleeder valve, you can really bugger them up because of this design and the fact that the radiator and the plugs are made of plastic.

The trick with either the drain plug or the bleeder valve is to GENTLY break them loose with a properly fitting wrench by wriggling them back an forth a little... this helps to get the o-ring seals inside un-stuck so the plug can actually move. Once broken loose, the pin will follow the path carved in the plug, (there may exist a reversed design where the pin is in the plug and the path is carved in the side of the hole), and the plug will pull itself up and out of the hole, allowing the fluid to flow or trapped air to escape as the case may be.

Dzus fasteners are excellent for aircraft body parts and similar applications, but for this application seems like the manufacturer is re-inventing the wheel to create unnecessary hassle for the owner so he or she has something else to take into the stealership to work on. If you happen to break a drain plug or a bleeder valve, it may result in having to replace the radiator.

It may be worthwhile to see if there is enough material surrounding the drain plug to drill out the entire darn thing and install a proper brass drain plug or drain petcock.

ok I got the radiator out and looked at it a little while ago. First the size open end wrench that fits it is 5/8 inch 17mm too big 15 mm too small 16mm may work if u have one. Second there are two small notch protrusions opposite each other that won't allow a socket to go on. I believe there is a special tool to remove but not really needed. A 10mm hex also fits inside the fitting I have pics but I always have trouble posting them here there is an o ring that could go bad and appears easily replaced but have to take it all the way out to change it . I had to pull out very firmly and unscrew past where it "stopped" initially with more force than i would have tried normally to get it out . Looks like it has to line up with two notches at bottom of hole to get started and with some pressure get it started then get to normal screw in and out portion.
If you pm me cell number can text pics easy now and will try to upload later

_________________
05 Blu LIM, OME GDE Tbo, wk II 245/75/17, KC Lights, bull bar, 195K H TC
05 Blu Lim, Dayton, GDE HT, 255/75/18 , 210K , H TC
06 Bla Lim, GDE Eco, Destination AT 245/75/17, 151K, H TC
06 D Khaki Lim 126K wkII Eur TC
05 D khaki Lim 145k refurbishing
All CRDS: Fumoto, Lift , Fan Shroud mod, fuel head Gen II, SAMCOS,self TB, 2 Mic filt, Hayden

Here are pics I think !!!
first is top of plug that shows the 10mm hex head access
https://imgur.com/bnwaqWe
next is the view of bottom of drain hole notice the two notches that i believe hold plug in unless lined up and extracted
https://imgur.com/LAIfWTv
next is the bottom of plug I believe the protrusion near top has to line up with gaps at female end in radiator then pus in a little and rotate
https://imgur.com/hxTiu5O
next is side pic of plug notice the o ring and the small grove near tip that i believe the tabs on female side in radiator have to turn in to line up again on male to go in further. I think this creates the "stop"
https://imgur.com/Gl6L1pe
another side view
https://imgur.com/Gl6L1pe
a view with plug as far out as it can normally go also note the tab on side that prevents an otherwise correct size 5/8 inch socket from going on.
https://imgur.com/0HUcqA3

I hope these came out ok and the links work, if so maybe I can remember how to do it now!!!

_________________
05 Blu LIM, OME GDE Tbo, wk II 245/75/17, KC Lights, bull bar, 195K H TC
05 Blu Lim, Dayton, GDE HT, 255/75/18 , 210K , H TC
06 Bla Lim, GDE Eco, Destination AT 245/75/17, 151K, H TC
06 D Khaki Lim 126K wkII Eur TC
05 D khaki Lim 145k refurbishing
All CRDS: Fumoto, Lift , Fan Shroud mod, fuel head Gen II, SAMCOS,self TB, 2 Mic filt, Hayden

With some help from TKB4, I now have a leak free cooling system, He took the time to take and post pictures so I would know what things looked like and be able to disassemble the drain cock without destroying something. My leak was caused by a broken O ring. Bought a new drain cock from Advance and installed it and now have a leak free cooling system again...(Doorman #61134 Head is the same as the vent on top of the radiator but internals are identical)

Thanks to all for your help...

_________________
Life's to short not to have fun !!!!

These photos are excellent! And they do indeed show that this petcock works similar to a Dzus fastener.

I never pulled the plug completely out, but you can indeed see a couple of wide stud-like protrusions in the plug hole that would fit in the wide grooves of the plug.

Glad to see that your explanation was spot-on. That and the photos got 2 CRD's out of what would otherwise be a vexing problem.

Good deal!

Anyone figured out why they used the odd size head with the ridges? It's like a no-tamper system or something.

Was the Dorman part the same head?

_________________
2005 Liberty CRD. New rockers, exhaust valves; Provent, EGR block & butterfly delete & V6 air box at 100K

1998 XJ 4.0L, 2" lift

First Jeep: 1962 Willys CJ-3B

I would have to assume they wanted to either sell a special tool or make it more unlikely to self service. These two small plastic tabs on outside of otherwise hexed like a bolt could be easily removed with dremel etc just hard to get to.

_________________
05 Blu LIM, OME GDE Tbo, wk II 245/75/17, KC Lights, bull bar, 195K H TC
05 Blu Lim, Dayton, GDE HT, 255/75/18 , 210K , H TC
06 Bla Lim, GDE Eco, Destination AT 245/75/17, 151K, H TC
06 D Khaki Lim 126K wkII Eur TC
05 D khaki Lim 145k refurbishing
All CRDS: Fumoto, Lift , Fan Shroud mod, fuel head Gen II, SAMCOS,self TB, 2 Mic filt, Hayden

The original poster indicated to me in a pm that he got the replacement plug at Advance auto and it was identical except the head and they swapped out the o rings that fixed the problem

_________________
05 Blu LIM, OME GDE Tbo, wk II 245/75/17, KC Lights, bull bar, 195K H TC
05 Blu Lim, Dayton, GDE HT, 255/75/18 , 210K , H TC
06 Bla Lim, GDE Eco, Destination AT 245/75/17, 151K, H TC
06 D Khaki Lim 126K wkII Eur TC
05 D khaki Lim 145k refurbishing
All CRDS: Fumoto, Lift , Fan Shroud mod, fuel head Gen II, SAMCOS,self TB, 2 Mic filt, Hayden

2 CRD's wrote the following on the replacement part:

"Doorman #61134 Head is the same as the vent on top of the radiator but internals are identical"

So 2 CRD's replacement radiator drain plug has that flat tab that you can grip with soft parallel jawed pliers, or your thumb and fingers if you are strong enough.