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Hey guys,

So I was installing my Saab intercooler this afternoon and when I set the intercooler into place, one of the nipples on the coolant box snapped right off! I wasn't even applying pressure!

Here's a photo of which nipple snapped off (not my pic): Picture

Has anyone else done this? Is there an easy fix? Is that hose even needed? Or do I have to find a whole new coolant box?

Thanks for any help!

-Seth

Goto the hardware store and get a threaded nipple with threads on one side, and the nipple on the other. If you can remove the coolant box, drill out the old nipple and bolt in the new one. You might need to seal it with some sillicone or something, but it doesnt seem like the end of the world or anything

-Brian

Happens to everyone . I'd bet at least half of the turbo owners on this board don't still have their original coolant filler tank on their cars.

Search for a post by legacy92ej22t about how to fix this. He came up with a great solution involving a hollow piece of all-thread.

Thanks for the quick replies guys! I beleive this is the thread you're talking about? http://bbs.legacycentral.org/viewtopic. ... highlight=

What is "all-thread"?

It's a word used to describe a rod that's threaded along its entire length:

Thats what I thought.

Well, I'm trying something different. I have this super-strong epoxy and I'm going to see if it'll work to just re-attach the nipple.

It's only been a couple hours and this epoxy is holding like a rock! I just added another coat to make sure there wont be any leaks.

Cool. Just remember to check it fairly often (especially at first) to make sure it stays sealed. At least every time you refuel, I'd say.

I am almost thinking about draining my cooling system, then doing Matt's fix, and then being done with it. I don't want to have to worry about breaking that nipple

I couldnt find any all-thread small enough for the little nipple, thats why I didnt do it.

Well that didn't work for too long... lasted for a couple days and then failed. Time to try something else.

Mine fell off one night. I had to buy a new one at subaru. I hate them so much.

How much was it?

How did it break off?

Was it due to lateral pressure?


I was thinking of a way to avoid this when installing my i/c later this summer.

TheShocker wrote:Well that didn't work for too long... lasted for a couple days and then failed. Time to try something else.

My fix has lasted me 5 months and about 11k miles. It's still good too. Never leaked a single drop of coolant. I would keep looking for the all-thread. Go to a lighting store (lamps) and I'm sure you'll find it. Good luck!

Oh, if you get completely sick of trying to deal with it do a search for "relocating coolant tank" or something like that. You can get a coolant tank off a WRX and they're metal. The thing is you'll have to relocate it up by the PS pump and obviously that means rerouting the coolant lines but it's been done successfully by a few members.

I had an alluminum one welded up for me. Just got it installed today. The car sat for a couple weeks though, and now the check engine light is on........ fix one thing and something else happens. How do I check engine codes anyway?

-Seth

Check the first sticky thread in the Engine forum.