I ordered a replacement tank from U.S.Plastics.com Cap( drill 1/8" vent hole in center of cap) and plastic hose barb ordered separately.
I now see I was mislead by your thread title, you said overflow tank. Now I see you really meant expansion tank, two entirely different things.
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2000 Winnebago Ultimate Freedom USQ40JD, ISC 8.3 Cummins 350, Spartan MM Chassis. USA IN 1SG 11B5MX,Infantry retired;Good Sam Life member,FMCA." My fellow Americans, ask not what your country can do for you, ask what you can do for your country. John F. Kennedy
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Thanks everyone! Once we jointly figured out mine was an expansion tank, and the specific type is an obsolete nylon one, it became obvious that the risk wasn't worth messing around with a plastics repair. I ordered an aluminum tank from Jim at Source Engineering today, as recommended in the thread. It looks like a great option. Thanks again!
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Steve P
2008 Monaco Knight 40DFT
2014 Honda CR-V LX toad
Got the new aluminum expansion tank installed yesterday. $238 labor, parts, radiator fluid and sales tax. $483 incl shipping for the tank from Source Engineering . Both the old and new were a tight fit and had to be turned every which way to get the old tank out and the new one in. The sight glass looks like a gun port! Imagine if you were following close and suddenly that utility hatch swings open!! Okay, so my imagination is a bit too vivid...
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Steve P
2008 Monaco Knight 40DFT
2014 Honda CR-V LX toad
Just finished replacing my old sun dried leaking expansion tank with the new aluminum tank from source engineering. I had to remodify/cutout the back of the plastic tank area (not the tank) in order to install new tank. This was not an easy swap out. If they could have taken an inch off the front to back and an inch off the side to side I think it could have been an easier swap. The new tank came with the low level sensor. Had to cut the side plastic for the sensor area. Still had to bring the top of tank out to fit. One reason new tank would not fit is the edges were not rounded like the plastic tank. Tank came with a 14psi cap which I swapped out with the 7psi cap that was on the plastic tank. I did look this up in my service manuals and it was rated at 7psi.
In your case I would consider changing. I changed mine about 6 years ago.
I contacted them at find my parts rv and they couldn't tell me whether the tank was corrosion resistant nor did they get back to me. To have a big sensor on the side ($48 dollars and plug harness 18 dollars and the two fittings on top $26 dollars) makes it hard to install. Source Engineering gives you the sensor with their tank (just connect the existing wire) and it is made of aluminum. The two fittings on top are a quarter inch pipe threads which I picked up at NAPA for $6 dollars each. I do not live close to a hardware store where I'm sure I could of got the fittings cheaper. If you have a tight area like mine I would suggest Source engineering. 2002 monaco knight
the back of the plastic tank area (not the tank) in order to install new tank. This was not an easy swap out. If they could have taken an inch off the front to back and an inch off the side to side I think it could have been an easier swap. The new tank came with the low level sensor. Had to cut the side plastic for the sensor area. Still had to bring the top of tank out to fit. One reason new tank would not fit is the edges were not rounded like the plastic tank. Tank came with a 14psi cap which I swapped out with the 7psi cap that was on the plastic tank. I did look this up in my service manuals and it was rated at 7psi.
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