220 Journey Surge tank leak

RKL2 · 05-25-2009, 09:33 PM

On my 2002 Journey 36GD (330 Cat rear radiator)) the plastic surge (coolant) tank has a crack that leaks under pressure...I remember a thread that talked about replacing it from under the bed (engine side of radiator) and some difficulty removing a metal support piece that was in the way....Has anyone replaced this tank and has advice and/or a part number. Looking at it sideways, it looks like an inverted "L" with the short part of the "L" extending out over the radiator.. thanks RKL

BattChief · 05-27-2009, 07:40 PM

I tried to change mine out while on the road, to no avail. Didn't have the tools or patience to do it like it should be done, so ended up having Freightliner in Amarillo change mine out. Learned a couple of "tricks". I didn't get to watch the mechanics do the job, but they insisted they didn't have to go under the bed. Seems like an easy enough job, but getting to a couple of the bolts was a bear!

Hint #1:
Remove the panel above the radiator from the outside. This will give you much better access to the tank, bolts and hoses.

Hint #2:
This one is from the mechanics.... They took a saw and CUT the tabs off the tank on the tow bolts next to side of the coach. Once the tank is out, removing the bolts is easy! The tabs attach to a piece of metal on the side, and they used nuts held in place by thin tin type nut holder that slide over the metal bracket. I'm trying to think of a circumstance these are used, because once I say them, I thought "No Brainer!", but my feeble mind won't let me remember.....

Hint #3:
Replace the clamps on the tank with regular worm screw hose clamps and get rid of the cheap wire ones they used at the factory!

Expect to have to add antifreeze a couple of times once the job is done. Took a couple of heat cycles to "burp" all the air from my system.

RKL2 · 05-28-2009, 07:15 AM

BattChief...thanks for the info....exactly what I was looking for......RKL

smlranger · 05-28-2009, 09:43 AM

I also had mine replaced at Freightliner in Gaffney, along with new rad hoses. We took everything out from under the bed and they never had to go there. What I was able to see thru the garage door window, they replaced the upper radiator hose and the surge tank from outside by removing an exterior panel above the radiator.

The mechanic confirmed later that the tank is accessed from the exterior of the coach. They are using a new design in the surge tank but they did advise me to make a rubber flap of some sort to shield the new tank from the sun.