Aluminum replacement for plastic rear coolant bypass joint

Does anyone have broken one kicking around? I'd like to design a metal one that's plug-n-play before I replace mine this summer.

 

I will help you in your quest Simple Jack.

 

Going to design some to sell?

 

Either I'll sell them, or I'll upload the drawings. Probably both.

 

Perfect! DM'd

 

Post 210 & 212 of this thread have pictures and info on the aftermarket’s solution to a plastic coolant piece on Corollas that’s prone to leak.

Here’s a solution for the plastic oil filter cooler assembly's on 3.6 liter Jeeps that’s also prone to leak (oil).

It would be nice to see something available for the 3.5 Toyotas.

 

We'll be waiting. Again.

 

I just picked my Chrysler van from the mechanic. Replaced that oil cooler on the 3.6L engine. Doorman all aluminum part with a lifetime warranty. 158xxx miles/14 years old van.

 

Do you have a 3D scanner? I have one that is fairly accurate- just need a model to work from.

Would aluminum 3D printing work for these? Several companies offer metal printing online like emachineshop.com and others. I used emachineshop’s laser service to build my racks and they did a great job.

 

I actually just got an Einstar and have been dying for something to make lol.
I havent looked into how 3d printed aluminum hold up to rapid temp/pressure swings yet, though I've used xometry's 3d printed aluminum in past for complicated, low production sprockets with good results.
I was thinking tube based for cost

 

How about cast using a 3D printed burn away model to use for making the mold?

 

Could be difficult to do diy effectively, and the mating surface would still need machined.

 

good choice

 

Took us a month to figure it out. Thought my transmission was leaking. Put in UV dye, could not find any ATF leaks. My guy pocked around more. Found drips on top of the bell housing, followed them up, found the leaky oil cooler. He said the valley between the blocks was filled with oil.
I have a great mechanic. Did not charge me any for all of diagnostics. Just labor and parts to replace the cooler and 2 sensors going into it.

 

Glad to hear you have a good mechanic.

This issue is common with Chrysler. So much so that when we are doing an oil change on a 3.6 and we see oil dripping on the exhaust crossover pipe or on the trans bell housing, like you stated, we get a flashlight and shine the light down into the engines valley to check if it’s wet. Of course, sometimes people spill oil there when replacing the filter but the one we did today was an obvious leak. The job pays 2.8 hours of labor.

 

How often do you get oil/coolant cross contamination from a leaky OEM cooler on 3.6?
We did not see any signs, but I am wondering if I should replace oil with 700 miles on it, just to be safe.
I will be doing drain and refills with G05 coolant, just because van is due for coolant change. Wondering if I should do oil as well.
PS oil cost is not an issue, I have 50 quarts of synthetic 5w-30 on hand. Just need to get a new filter (it is a different size than my old one).

 

I haven’t seen that happen once but we do maybe 10 of these a year at most. Today’s customer had her oil changed 1000 miles ago. We didn’t see any reason to change it out. I’m OCD so I personally would do so but haven’t seen any signs of contamination otherwise.

 

Here's a basic .stl of the coolant bypass. I still need to make a more fab friendly model when I get some free time.
One with an O-ring groove for a -029 O-ring, the other has a flat face for easy modification or some cut gasket

 

I still have my broken one, if you need it.

 

Thanks, but I think im set for now, I just ended up drunk ordering one off ebay lol