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55-56 Mopar heater core removal question
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56D500boy
Posted 2021-03-21 2:50 PM (#610207)
Subject: 55-56 Mopar heater core removal question



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I probably have a heater core leak. I know that I will have to remove the heater ducting box (Item 19) on the engine bay side but will I also have to remove the inner ducting (Item 47) with the defroster motor to access the bolts/nuts holding the heater core to the firewall?

I just want to be mentally prepared for this next can o'worms.



Edited by 56D500boy 2021-03-21 2:51 PM
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Powerflite
Posted 2021-03-22 12:06 AM (#610224 - in reply to #610207)
Subject: Re: 55-56 Mopar heater core removal question



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No, the heater core is bolted to the heater box, so once you take it off, the core will come with it, along with the insulation pad #18. You will definitely have to remove the distributor cap though, and possibly the distributor as well. Spark plug wire covers will likely need to come off as well.
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56D500boy
Posted 2021-03-22 1:59 AM (#610226 - in reply to #610224)
Subject: Re: 55-56 Mopar heater core removal question



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Powerflite - 2021-03-21 9:06 PM
No, the heater core is bolted to the heater box, so once you take it off, the core will come with it, along with the insulation pad #18. You will definitely have to remove the distributor cap though, and possibly the distributor as well. Spark plug wire covers will likely need to come off as well.


And so the can opens.

Dels56 sent me a few photos (thanks muchly Del) of his 56 Dodge with the heater box removed from the firewall, showing the defroster box still in place. I am happy that a) the heater core comes off with the heater box and b) that the heater core looks (or can look) "normal" (like a small radiator). Some of the ones that I've seen look more like a bee's honeycomb.

UPDATE: But on reviewing the photos, I still don't know how the heater core and it's flange are attached to the heater box.

Del's photos:



Edited by 56D500boy 2021-03-22 12:25 PM




(Dels56DodgeHeaterBoxRemoved.jpg)



(Dels56DodgeHeaterBoxRemoved_WithHeaterCore.jpg)



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Attachments Dels56DodgeHeaterBoxRemoved.jpg (140KB - 308 downloads)
Attachments Dels56DodgeHeaterBoxRemoved_WithHeaterCore.jpg (132KB - 313 downloads)
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56D500boy
Posted 2021-03-23 2:13 AM (#610267 - in reply to #610224)
Subject: Re: 55-56 Mopar heater core removal question



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Powerflite - 2021-03-21 9:06 PM
No, the heater core is bolted to the heater box, so once you take it off, the core will come with it, along with the insulation pad #18. You will definitely have to remove the distributor cap though, and possibly the distributor as well. Spark plug wire covers will likely need to come off as well.


Nathan: If I remove the heater fan (and motor) from the heater box, do you still think that I would have to remove the distributor stuff? (I would remove the fan and the air cleaner). My biggest concern now is getting at the two bolts hidden by the PB accordion booster without removing the booster.

Your 56 Belvedere:



Mine (56 Dodge D500 engine):



Edited by 56D500boy 2021-03-23 2:16 AM




(DForgies56D500EngineBayJuly11_2017_small.jpg)



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Attachments DForgies56D500EngineBayJuly11_2017_small.jpg (152KB - 319 downloads)
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Powerflite
Posted 2021-03-23 11:14 AM (#610276 - in reply to #610207)
Subject: Re: 55-56 Mopar heater core removal question



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You'll just have to give it a try. I know it's a tight fit to get to those bottom screws. The '56 is easier to access than the '57-up, so that's in your favor.
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56D500boy
Posted 2021-03-23 12:41 PM (#610279 - in reply to #610276)
Subject: Re: 55-56 Mopar heater core removal question



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Powerflite - 2021-03-23 8:14 AM
You'll just have to give it a try. I know it's a tight fit to get to those bottom screws. The '56 is easier to access than the '57-up, so that's in your favor.


I was playing at it yesterday. I think that I can get the bolt immediately behind the distributor with a long extension on my 1/4" rachet (3/8" socket). Interesting (or not), I seem to be missing a lot of the bolts that I think should have been there (I think there were supposed to be something in the order of 20, I probably only have 14 or so in place to remove. No idea why they aren't there).

I used my "endoscope" to look for the two bolts that should be behind the PB booster but I didn't see them. Not sure if they are actually not there or I just didn't see them. Might have to remove or loosen the booster to get a better look.

Crink Crink Crink



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dels56
Posted 2021-03-24 12:18 PM (#610307 - in reply to #610207)
Subject: Re: 55-56 Mopar heater core removal question


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Dave, You are correct. The bottom bolts are a bugger to get at. Looked at my notes and I did have the dizzy out, carb off and the blower motor off. And for an old fellow like me I twisted and turned to get at the bolts. I replaced all the rusted old bolts n screws. Some of the threads in the firewall were rusted out so I repaired them with Rivnuts and ran a tap through the rest. After cleaning the old gasket off the firewall and new bolts in by the master cylinder (no power booster in the way) it went back together quite easy.
Del S

Edited by dels56 2021-03-24 1:37 PM
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56D500boy
Posted 2021-03-30 9:01 PM (#610541 - in reply to #610207)
Subject: RE: 55-56 Mopar heater core removal question



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56D500boy - 2021-03-21 11:50 AM .
I probably have a heater core leak. I know that I will have to remove the heater ducting box (Item 19) on the engine bay side but will I also have to remove the inner ducting (Item 47) with the defroster motor to access the bolts/nuts holding the heater core to the firewall?
I just want to be mentally prepared for this next can o'worms.


Went for a drive in the 56 Dodge yesterday. In addition to losing a Dog Dish hub cap (my fault) , I came home to find that the heater core was flowing out the bottom of the flange on the fiberglas plenum. Not good.

I had wanted to drive the car again today but I finally realized that that would just be asking for trouble. Therefore, this afternoon, I tackled the removal of the heater plenum and the heater core.

First thing was to remove the heater fan and lay it aside. Next was "all" the bolts (3/8" head). I got smart on the more accessible ones and used my cordless drill loaded with a 3/8" shafted socket. Some of the others, especially the two (that I had) nearest the engine. I had to use my small 1/4" drive ratchet and a deep 3/8" drive socket to get them. For reasons not clear to me, I am missing many of the bolts that I know should have been there. Oh well.

I had to cut the hoses off the two heater core spigots and the heater valve (which is now going to be replaced) while I am there. I gently pried the plenum away from the firewall and was able to carefully side it out without touching the distributor. With everything out, I could see anything obvious other than the wet rust showing in the interior of the spigots.

With the plenum off, I can see the four firewall studs that I think are there to take the weight of the core and coolant. It also uses a separate rubber gasket that has nothing to do with the insulated part of the plenum. More challenges.

Off to the rad shop (or shops) tomorrow.

Some photos from today:



Edited by 56D500boy 2021-03-30 9:07 PM




(56DodgeHeaterBlowerPlenum_Before_LeftSide.jpg)



(56DodgeHeaterBlowerPlenum_Before_RightSide.jpg)



(56DodgeHeaterBlowerPlenum_After_RightSide.jpg)



(56DodgeHeaterBlowerPlenum_Removed_BackSide.jpg)



(56DodgeHeaterBlowerPlenum_Removed_HeaterCoreFlippedOver.jpg)



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Attachments 56DodgeHeaterBlowerPlenum_Before_RightSide.jpg (168KB - 308 downloads)
Attachments 56DodgeHeaterBlowerPlenum_After_RightSide.jpg (169KB - 311 downloads)
Attachments 56DodgeHeaterBlowerPlenum_Removed_BackSide.jpg (155KB - 316 downloads)
Attachments 56DodgeHeaterBlowerPlenum_Removed_HeaterCoreFlippedOver.jpg (222KB - 310 downloads)
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geoffs60
Posted 2021-03-31 12:46 AM (#610544 - in reply to #610207)
Subject: RE: 55-56 Mopar heater core removal question


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I hope you find the core leaks, In my case a number years ago on a 56 windsor I went thru the same exercise to find nothing wrong with the core, but what must have been a poor lower U shaped hose fit or a weak clamp which allowed water to run into the heater box and leak out indicating a poor core.. which it wasnt. Maybe a 30 minute fix with a new hose and clamp could have saved an aggravating long job. i will be double checking next time before i pull a 56 heater box..
Good luck.
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56D500boy
Posted 2021-03-31 4:17 PM (#610563 - in reply to #610544)
Subject: RE: 55-56 Mopar heater core removal question



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geoffs60 - 2021-03-30 9:46 PM
I hope you find the core leaks, In my case a number years ago on a 56 windsor I went thru the same exercise to find nothing wrong with the core, but what must have been a poor lower U shaped hose fit or a weak clamp which allowed water to run into the heater box and leak out indicating a poor core.. which it wasnt. Maybe a 30 minute fix with a new hose and clamp could have saved an aggravating long job. i will be double checking next time before i pull a 56 heater box..


Well, maybe I have good news and maybe I have bad news. Before I took the heater core to a local(ish) shop to get the core replaced, I did a static test (laying the core flat and filling it through the two inlet/outlet spigots). Not much pressure, I realize, but no leaks that I could see. So I decided to take it to a shop about 20 miles away because they said that they would test the core first before they went ahead with any repairs (up to and including a core replacement).

The test took about 10 minutes. The young tech hooked up an air hose (on a regulator) on one spigot and plugged the other. Then he emersed the core in their large 8 ft x 8 ft x 1 ft deep testing tank and applied air pressure to about 10 psig. Nothing. He flipped the core over and tested again, still nothing. He said the spigots were a bit egged (oval) and that might have meant the hose is what was leaking. He used a tool to round out the spigots and said that I was good to go. No charge. Thanks!!

On the way home, I went by an uphostery shop that used Marine vinyl and ordered a yard of "Baby Blue" vinyl to create a patch for the sides of my lower front seat (they all crack on the seat sides).

So other than the gas that I burned, I would say "Good news" (no $250 heater core). "Bad news" is I have to put everything back together. I've already run my tap through some of the bolt holes in the firewall to help make sure that reassembly goes smoothly.

I will make lemonade whenever I get lemons so there will be some other "improvements" as I put things back together. (I hope).



Edited by 56D500boy 2021-03-31 7:45 PM
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geoffs60
Posted 2021-03-31 6:28 PM (#610569 - in reply to #610207)
Subject: RE: 55-56 Mopar heater core removal question


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Thats good news on not having to spend $$ on a new core, yes same trap I fell into , the lower hose sits well up against the heater hsg and any water leak directly from the hose is all but impossible to see other than the dribble out of the bottom of the hsg which to me and know doubt most would take to be a leaking core. good luck on the reinstallation.
Geoff
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Powerflite
Posted 2021-03-31 7:13 PM (#610570 - in reply to #610207)
Subject: Re: 55-56 Mopar heater core removal question



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Good to know. Thanks Geoff! I don't usually bother to connect up the heater cores because I rarely would ever use them, but this is definitely worth remembering in case I do decide to make them work.
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56D500boy
Posted 2021-04-02 2:41 AM (#610615 - in reply to #610541)
Subject: RE: 55-56 Mopar heater core removal question



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When I got the heater plenum off the firewall, I think I was going to reuse the insulation pad when I reinstalled the plenum. I thought about it over night and decided no. I decided to use some of the materials that I had left over from when I insulated the floor before I installed the new carpet. This included some Eastwood X-mat low profile (which is like Dynamat) and Eastwood foam core X-Mat High Profile. I put a layer of the low profile X-mat into the flat pan first and then a layer of the foam core High profile X-mat on top of that. Then I sealed the edges with some aluminum tape. I wore latex gloves but still managed to get a small poke that drew blood. Left some DNA behind for CSI to clone me 100 years from now (LOL)

Then I decided to paint the final layer with Tremclad Professional (fast drying) semi-gloss black. It wasn't happy trying to stick to the aluminum foils so I will have to add another coat before I reinstall the plenum. Tomorrow I need to go to Lowes so get some materials for the edge of the Plenum.

Hopefully, my material choices will be fine.

Today:



Edited by 56D500boy 2021-04-02 2:45 AM




(56DodgeHeaterPlenumPreppedForNewInsulation.jpg)



(56DodgeHeaterPlenum_FirstLayerOfNewInsulation.jpg)



(56DodgeHeaterPlenum_SecongLayerOfNewInsulation.jpg)



(56DodgeHeaterPlenum_FirstLayerOfNewInsulation_FirstCoatOfPaint.jpg)



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Attachments 56DodgeHeaterPlenum_FirstLayerOfNewInsulation.jpg (138KB - 302 downloads)
Attachments 56DodgeHeaterPlenum_SecongLayerOfNewInsulation.jpg (128KB - 303 downloads)
Attachments 56DodgeHeaterPlenum_FirstLayerOfNewInsulation_FirstCoatOfPaint.jpg (148KB - 294 downloads)
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Powerflite
Posted 2021-04-02 3:36 PM (#610621 - in reply to #610207)
Subject: Re: 55-56 Mopar heater core removal question



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Dave, this is the stuff that I used to seal the box to the firewall. It remains flexible over time and is basically the same stuff the factory used. But I would find some of this in a black color instead. The white really stood out after I was finished.
https://www.ebay.com/itm/1964-72-GM-Firewall-Kick-Panel-Heater-Box-S...




(Firewall box sealant.jpg)



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Attachments Firewall box sealant.jpg (27KB - 304 downloads)
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56D500boy
Posted 2021-04-02 6:36 PM (#610627 - in reply to #610621)
Subject: Re: 55-56 Mopar heater core removal question



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Powerflite - 2021-04-02 12:36 PM
Dave, this is the stuff that I used to seal the box to the firewall. It remains flexible over time and is basically the same stuff the factory used. But I would find some of this in a black color instead. The white really stood out after I was finished


Thanks Nathan. I went out to Lowes and they didn't know what I was talking about ("Rope Caulk"). Ended up at Canadian Tire and found it in grey as Moretite brand rope caulk beside a bunch of black foam double-sided weather stripping foam tapes.

https://www.canadiantire.ca/en/pdp/frost-king-mortite-rope-caulk-90-...

Decisions decisions.

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56D500boy
Posted 2021-04-11 9:06 PM (#610917 - in reply to #610627)
Subject: Re: 55-56 Mopar heater core removal question



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Ended up buying and using the 1" wide self-sticking closed-cell weatherstripping around the edge of the plenum. Made a new rubber gasket for the heater core. Punched all the appropriate holes. Added 1/4" wide self-sticking weather stripping between the heater core and the plenum. (The rubber gasket goes between the heater core mounting flange and firewall).

After running a 1/4" x 20 tap through all the threaded holes in the fire wall used to mount the plenum, I first tried loosely mounting the heater core to the firewall and then adding the plenum over it. NOPE. Not enough room to get the plenum over the lower heater core nipple (bangs into the permanent wheel well liner).

Okay so the heater core has to be loaded into the plenum first. Because of the extra weight, I decided to cut some 1/4" x 20 threaded rod to use to align and hang the plenum on the firewall while I start to add the plenum bolts. That worked well.

Getting the bolts in the bottom of the plenum, especially near the engine was a challenge. However, I refused to remove the distributor and got the job done.

That left adding the new (Volvo) heater valve and hoses (there were some issues with the heater valve mounting so I will do a separate post on that). Finished that yesterday. Added a cooling system flushing "Tee" to the heater core inlet hose (actually the hose to the upper nipple of the heater valve).

Today, I added the coolant that I had drained from the heater hoses when they came off back into the rad. Started the car and put it on the street to get better room and light to do some finishing touches, including reinstalling the heater fan. Added some more water to the rad. Let the engine run to get up to temp (and pressure (7.5 lb cap)).

Then I saw the trickle of coolant coming out of the bottom of the plenum by the lower heater core nipple.

Guess what I am doing tomorrow?

Edited by 56D500boy 2021-04-11 9:10 PM




(56DodgeReinstallationOfHeaterCoreAndPlenum_FireWallCleanedUpAndNewHeaterCoreGasketMadeAndInstalled.jpg)



(56DodgeReinstallationOfHeaterCoreAndPlenum_With1inchWideClosedCellFoamWeatherStrippingAndHeaterCore.jpg)



(56DodgeReinstallationOfHeaterCoreAndPlenum_PlenumAndCoreOnTheFirewallReadyForHoses.jpg)



(56DodgeReinstallationOfHeaterCoreAndPlenum_OnlyTheHeaterFanToGo.jpg)



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Attachments 56DodgeReinstallationOfHeaterCoreAndPlenum_FireWallCleanedUpAndNewHeaterCoreGasketMadeAndInstalled.jpg (168KB - 297 downloads)
Attachments 56DodgeReinstallationOfHeaterCoreAndPlenum_With1inchWideClosedCellFoamWeatherStrippingAndHeaterCore.jpg (189KB - 306 downloads)
Attachments 56DodgeReinstallationOfHeaterCoreAndPlenum_PlenumAndCoreOnTheFirewallReadyForHoses.jpg (209KB - 299 downloads)
Attachments 56DodgeReinstallationOfHeaterCoreAndPlenum_OnlyTheHeaterFanToGo.jpg (146KB - 298 downloads)
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Powerflite
Posted 2021-04-11 9:45 PM (#610922 - in reply to #610207)
Subject: Re: 55-56 Mopar heater core removal question



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It sounds like it may be a stress crack between the joint of the nipple as it goes into the core. Outside, it seems OK, but put it under pressure & weight, and it starts to leak. The lower hose connection on my radiator had that issue and I was able to solder it back up by using an ample amount of acid-flux.
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56D500boy
Posted 2021-04-12 2:03 AM (#610928 - in reply to #610922)
Subject: Re: 55-56 Mopar heater core removal question



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Powerflite - 2021-04-11 6:45 PM
It sounds like it may be a stress crack between the joint of the nipple as it goes into the core. Outside, it seems OK, but put it under pressure & weight, and it starts to leak. The lower hose connection on my radiator had that issue and I was able to solder it back up by using an ample amount of acid-flux.


Thanks Nathan. I think that you will be right. I took the car for a 10 mile spin and the parked it in the garage. Later I went back out and checked for a puddle under the passenger side of the car. Nothing. So it leaks but not seriously (for now).

I think that I will figure out how to make a heater core test kit with Schraeder valve, some heater hose, a copper plug and some hose clamps. I have at least one container big enough to fill with water and test the heater core with a bicycle pump (with a pressure gauge) to around 10 psi. I think that when the rad shop tested the core, their test hoses must have covered the crack (or pin hole). If I can find the fault, I might be able to get out the old plumbers propane torch and solder the problem. (I hope).

At this point, I am going to finish putting the fan back in (just three bolts and two wire connections) and see what happens coolant leakage wise. At least I know how to remove and replace the core and the plenum and I've cleaned everything up so doing a Re and Re will be much faster the next time.

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56D500boy
Posted 2021-04-22 11:21 PM (#611312 - in reply to #610928)
Subject: Re: 55-56 Mopar heater core removal question



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56D500boy - 2021-04-11 11:03 PM
I think that I will figure out how to make a heater core test kit with Schraeder valve, some heater hose, a copper plug and some hose clamps. I have at least one container big enough to fill with water and test the heater core with a bicycle pump (with a pressure gauge) to around 10 psi. I think that when the rad shop tested the core, their test hoses must have covered the crack (or pin hole). If I can find the fault, I might be able to get out the old plumbers propane torch and solder the problem. (I hope).


I did install the heater fan and ran the car for a few days. There was leakage (some). I finally decided to remove the core again and test it. Bought some Schraeder valves and heater hose and clamps. Removed the core yesterday (took an hour - some of those bolts are just hard to get at). Tested the core today.

I had intended to test at 10 psi but my bicycle pump with gauge got it above 10 psi very quickly so I left it above 10 psi. Eventually, I went to 2 bar (29 psi) and it sat there for at least 4 hours and did not leak (the core was in a plastic sweater box filled with water - no bubbles).

Conclusion: The issue must be the way that it was clamped before and then again after I re-installed it after the rad shop tested it before and found no leaks. I am now on the hunt for a better clamp (than a gear clamp). I am looking at Mikalor clamps.

Today:





(SettingUpToTest56DodgeHeaterCoreUnderPressure.jpg)



(Testing56DodgeHeaterCoreUnderPressure.jpg)



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Attachments SettingUpToTest56DodgeHeaterCoreUnderPressure.jpg (243KB - 286 downloads)
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Powerflite
Posted 2021-04-23 12:49 AM (#611314 - in reply to #610207)
Subject: Re: 55-56 Mopar heater core removal question



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Did you wiggle the pipes while it was under pressure?
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56D500boy
Posted 2021-04-23 3:08 AM (#611315 - in reply to #611314)
Subject: Re: 55-56 Mopar heater core removal question



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Powerflite - 2021-04-22 9:49 PM
Did you wiggle the pipes while it was under pressure?


Oh for sure. Nada.

I think tomorrow I will try installing the heater core with inlet and outlet hoses but no plenum and test whether it leaks. But first I need to find some better clamps than the Tridon gear clamps that I have used.

Maybe these Breeze clamps:



Or a Mikalor clamp:

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56D500boy
Posted 2021-04-24 2:32 AM (#611375 - in reply to #611315)
Subject: Re: 55-56 Mopar heater core removal question



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56D500boy - 2021-04-23 12:08 AM
I think tomorrow I will try installing the heater core with inlet and outlet hoses but no plenum and test whether it leaks. But first I need to find some better clamps than the Tridon gear clamps that I have used.
Maybe these Breeze clamps....or a Mikalor clamp


Ended up buying both the smooth inside Breeze clamps (at Napa) and some Mikalor N75-2527 T-bolt type clamps (at a NewLine hose shop). Not sure which ones I will end up using (maybe a combo).

Mikalor info:



Edited by 56D500boy 2021-04-24 2:35 AM




(MikalorN75-2527_W2_StainlessClampDetails.jpg)



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56D500boy
Posted 2021-04-26 7:13 PM (#611456 - in reply to #611315)
Subject: Re: 55-56 Mopar heater core removal question



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56D500boy - 2021-04-23 12:08 AM
I think tomorrow I will try installing the heater core with inlet and outlet hoses but no plenum and test whether it leaks.


Well, a few days passed. I installed the heater core on the 4 factory firewall studs (and one 1/4 x 20 nut). I put the hoses on the two heater core spigots using the Mikalor clamps. Filled the rad with water (to replace the coolant that came out more recently). Started the car to build up pressure (the 7.5 lb rad cap was on). Walked away. Talked to the neighbours (for too long).

When I got back to the garage there was liquid seeping on the floor (not a good sign). Peaked under the open hood and coolant was leaking from the upper spigot area and dripping down onto the lower spigot and the firewall and down to the floor.

Wiggled the top hose and more water came out of the top spigot area from under the hose. I tried tightening the clamp but it didn't help.

I have suspicion that the spigot is somehow split and tightening the clamp just makes the split worse. But I can't confirm until things cool off and I can remove the hose without burning myself.

At least the area of concern has been narrowed down.

News at 8.



Edited by 56D500boy 2021-04-26 7:14 PM
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56D500boy
Posted 2021-04-26 11:27 PM (#611466 - in reply to #611456)
Subject: Re: 55-56 Mopar heater core removal question



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56D500boy - 2021-04-26 4:13 PM
I have suspicion that the spigot is somehow split and tightening the clamp just makes the split worse. But I can't confirm until things cool off
and I can remove the hose without burning myself.

At least the area of concern has been narrowed down.


After things cooled down, I removed the upper hose and examined the spigot for cracks. Didn't see any.

Found the NAPA Balkamp 705-1212 lined gear clamps and installed one over the end of the hose.

Cleaned off the spigot with some 200 grit sand paper and put the hose and the Balkamp clamp on. I had noted where the roll bead was on the spigot and made sure that the clamp was on the downstream side of the roll bead. Tightened it reasonably.

Added water and refired the engine. Once up to temperature (and pressure), there was no leakage. I think the most recent issue (earlier this afternoon) was the Mikalor clamp, either its wider width or my positioning of the clamp. (???)

Should be good to go now.





(NapaBalkamp705-1212LinedGearClamp.jpg)



(InsituHeaterCoreTestingWithNapaBalkamp705-1212ClampOnTopAndMikalorClampOnBottom.jpg)



Attachments
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Attachments NapaBalkamp705-1212LinedGearClamp.jpg (23KB - 287 downloads)
Attachments InsituHeaterCoreTestingWithNapaBalkamp705-1212ClampOnTopAndMikalorClampOnBottom.jpg (153KB - 277 downloads)
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56D500boy
Posted 2021-05-04 11:49 PM (#611725 - in reply to #611466)
Subject: Re: 55-56 Mopar heater core removal question



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56D500boy - 2021-04-26 8:27 PM
Added water and refired the engine. Once up to temperature (and pressure), there was no leakage. I think the most recent issue (earlier this afternoon) was the Mikalor clamp, either its wider width or my positioning of the clamp. (???) Should be good to go now.


Installed the heater core with the plenum (but only two bolts above the heater core). Added the same hoses in the same locations as the no-plenum no-leak test the other. Cranked the clamps and filled the rad with water. Started the engine and let the cooling system come up to temperature and pressure.

FKMe. Leak. Small.

Stopped engine. Released pressure. Repositioned hose and clamp. Started and engine and got it up to temp and pressure. Leak but much smaller.

That upper spigot shows signs of a previous repair (soldered a split I think). Spigot wants to egg under clamp pressure. I have an idea in my head as how to fix the problem (new spigot pipe) but I will need to run it by a rad shop to see if they can do it. Core is fine. Upper spigot is NOT.

On the upside, I am slowly winning on the rear bumper valence project and will be moving to the final coats of paint tomorrow.




Edited by 56D500boy 2021-05-04 11:53 PM
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56D500boy
Posted 2021-05-07 2:26 AM (#611802 - in reply to #611725)
Subject: Re: 55-56 Mopar heater core removal question



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56D500boy - 2021-05-04 8:49 PM
I have an idea in my head as how to fix the problem (new spigot pipe) but I will need to run it by a rad shop to see if they can do it. Core is fine. Upper spigot is NOT.


I phoned ahead to the rad shop yesterday morning and determined that they knew what they were doing and had the required new upper spigot (copper pipe with a roll bead) needed for the fix. Took it out to the shop (about 20 miles away) after lunch and left it with them. He said should be ready about the same time (2 PM) tomorrow.

10 AM today they phoned and said it was ready. Off I went and was back home for lunch.

The original upper spigot was previously damaged and fixed sometime in the previous 65 years but it was weak and distortable with almost no remaining roll bead. The solution was to cut off the original spigot leaving about 1/2" above the insulation flange. Then they flared the stub and soldered in a new spigot, giving me about 1/2" extra length to play with. They wanted to do the same with the lower spigot but I said no, it is fine and besides the extra length can not be tolerated in that position because of the proximity to the wheel house.

After the repair to the upper spigot, they said that they pressure tested the repaired core to 18 psi and it was fine. Okalee Doakalee then.

After lunch, I put the repaired core in the plenum and installed the plenum and core on the firewall with just a few bolts. I wanted another test.

I hooked up the hoses again with the wider Mikalor clamp on the bottom spigot and the narrower "lined" Balkamp gear clamp on the top spigot. Filled the rad again and started the engine. Everything looked fine. Well until the cooling system got up to pressure. And then the core leaked somewhere. Water coming out from the bottom of the plenum near the lower spigot. I was NOT happy. My neighbour had to come over to see what the cursing was all about.

Shut the engine off. Let things cool. Remove hoses. Remove plenum and core. Reinstall core alone on the firewall. Add hoses, this time with the narrower lined Balkamp gear clamp on the bottom hose and the wider Mikalor clamp on the top hose. Filled rad with water and started engine again. Once up to temp and pressure, no leaks. Thank goodness.

So the issue seems to be the Mikalor clamp it NOT happy on the lower spigot because of its width and the length of the available spigot and probably me clamping partially in the roll bead instead of totally on the "flat".

Tomorrow I will remove the core from the firewall and re-install with the plenum and the hoses with the lined Balkamp gear clamps and NO Mikalor clamps. On last test before I install with the 20 plenum bolts.

Photos from today starting with the old damaged spigot, then the new spigot and finally the successful test this afternoon.


Edited by 56D500boy 2021-05-07 1:40 PM




(56DodgeHeaterCoreDamagedUpperSpigot_Before.jpg)



(56DodgeHeaterCoreDamagedUpperSpigot_After.jpg)



(56DodgeHeaterCoreDamagedUpperSpigot_After_OnTestNo2.jpg)



Attachments
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Attachments 56DodgeHeaterCoreDamagedUpperSpigot_Before.jpg (101KB - 271 downloads)
Attachments 56DodgeHeaterCoreDamagedUpperSpigot_After.jpg (146KB - 274 downloads)
Attachments 56DodgeHeaterCoreDamagedUpperSpigot_After_OnTestNo2.jpg (161KB - 271 downloads)
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56D500boy
Posted 2021-05-07 9:14 PM (#611825 - in reply to #611802)
Subject: Re: 55-56 Mopar heater core removal question



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56D500boy - 2021-05-06 11:26 PM
Tomorrow I will remove the core from the firewall and re-install with the plenum and the hoses with the lined Balkamp gear clamps and NO Mikalor clamps. On last test before I install with the 20 plenum bolts.


So that is what I did. Re-installed with the plenum and then tested.

Found a decent trick during the re-install: Although you can't install the heater core and then the plenum (not enough room for the plenum to clear the lower heater core spigot), once you have the core loose in the plenum and close to the firewall, you can separate the core from the plenum and hang the core frame on the upper two studs and then push the plenum closer. Otherwise, its a bit of a beotch.

Hooked up all the hoses properly (including the loop hose from the heater valve to the lower heater core spigot). Used the Balkamp lined gear clamps. Paid attention to the location of the clamp relative to the roll bead on the heater core spigots and the heater valve and then tightened them a reasonable (but not crazy) amount. Filled the rad. Started the car, got it up to temp and pressure AND THEN.....

Nothing What?? No leak?? I can't believe it.

Yay

Edited by 56D500boy 2021-05-07 9:16 PM
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wizard
Posted 2021-05-08 2:27 AM (#611826 - in reply to #610207)
Subject: Re: 55-56 Mopar heater core removal question



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Great thread Dave, thanks' for sharing every step, ups and Downs.
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Stroller
Posted 2021-05-09 11:14 AM (#611852 - in reply to #610207)
Subject: Re: 55-56 Mopar heater core removal question


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Ok I guess me glad my '56 has the gas heater lol. Be glad you don't have the darn defroster blower inside under the dash. If I ever have go under the dash again in my '56 I want a trained spider monkey that knows how to read an FSM.
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56D500boy
Posted 2021-05-09 1:26 PM (#611856 - in reply to #611852)
Subject: Re: 55-56 Mopar heater core removal question



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Stroller - 2021-05-09 8:14 AM
Ok I guess me glad my '56 has the gas heater lol. Be glad you don't have the darn defroster blower inside under the dash. If I ever have go under the dash again in my '56 I want a trained spider monkey that knows how to read an FSM.


LOL. All the 55-56s have the defroster fan on the inside, under the dash, including my 56 Dodge. I don't think it's a biggy. A 1/4" stubby rachet set is your friend.

https://www.leevalley.com/en-ca/shop/tools/hand-tools/wrenches-and-r...

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Stroller
Posted 2021-05-09 1:50 PM (#611857 - in reply to #610207)
Subject: Re: 55-56 Mopar heater core removal question


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yep and a trained spider monkey.
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NC Adventurer
Posted 2021-05-22 11:01 AM (#612170 - in reply to #610917)
Subject: Re: 55-56 Mopar heater core removal question


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56D500boy - 2021-04-11 9:06 PM

.
Ended up buying and using the 1" wide self-sticking closed-cell weatherstripping around the edge of the plenum. Made a new rubber gasket for the heater core. Punched all the appropriate holes. Added 1/4" wide self-sticking weather stripping between the heater core and the plenum. (The rubber gasket goes between the heater core mounting flange and firewall).

After running a 1/4" x 20 tap through all the threaded holes in the fire wall used to mount the plenum, I first tried loosely mounting the heater core to the firewall and then adding the plenum over it. NOPE. Not enough room to get the plenum over the lower heater core nipple (bangs into the permanent wheel well liner).

Okay so the heater core has to be loaded into the plenum first. Because of the extra weight, I decided to cut some 1/4" x 20 threaded rod to use to align and hang the plenum on the firewall while I start to add the plenum bolts. That worked well.

Getting the bolts in the bottom of the plenum, especially near the engine was a challenge. However, I refused to remove the distributor and got the job done.

That left adding the new (Volvo) heater valve and hoses (there were some issues with the heater valve mounting so I will do a separate post on that). Finished that yesterday. Added a cooling system flushing "Tee" to the heater core inlet hose (actually the hose to the upper nipple of the heater valve).

Today, I added the coolant that I had drained from the heater hoses when they came off back into the rad. Started the car and put it on the street to get better room and light to do some finishing touches, including reinstalling the heater fan. Added some more water to the rad. Let the engine run to get up to temp (and pressure (7.5 lb cap)).

Then I saw the trickle of coolant coming out of the bottom of the plenum by the lower heater core nipple.

Guess what I am doing tomorrow? ;)


Hey Dave,

I wanted to say thanks for the idea about using the closed cell foam to seal the heater box to the firewall. I recently pulled mine to check the heater core and noticed the sealant on the box and firewall was past its prime. I wasn't relishing trying to use silicone on it and getting it lined up without smearing it all over the place. The foam worked very well. I did use some clear silicone around the very edges to give it a smooth finish.

Thanks a million for the great idea.

BTW, your car is looking great!
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