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Old 05-15-2022, 10:35 PM   #1
Ali
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Aqua-Hot Hydro-Hot (Giant) Radiator Cap Removal

I am trying to open this (giant) radiator cap on my 1999-2000's Hydro-Hot 2001-E unit in order to flush/fill anti-freeze.

I tried twisting, even applied some force to it. It won't budge, seems seized or stuck.

Is there a trick opening these super large radiator caps?
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Old 05-16-2022, 08:37 AM   #2
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Aqua Hot

Looks like it is probably going to come off in pieces. IF you try to turn it off with any kind of extra force be aware that the neck it is attached to is silver soldered to a steel tank AND is easily twisted off or cracked creating a leak and bigger problems than you now have.

It looks like you have plenty of room to cut the edges working carefully with a Dremel tool.

Wish mine was that easy to access...most are not, they must have made a mistake in not burying it.
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Old 05-16-2022, 10:30 AM   #3
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Quote:
Originally Posted by Twomed View Post

Wish mine was that easy to access...most are not, they must have made a mistake in not burying it.
Ha!

Mine is as accessible as that !
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Old 05-16-2022, 10:46 AM   #4
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Besides the obvious push down hard while turning past the locks ? I don’t know. Mine has 3” of access at the top to the roof of the bay, making it difficult.
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Old 05-16-2022, 05:28 PM   #5
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I would suggest spraying with the stray some WD-40 UP in as best as you can soak up drips. There's better penetrating oil but most really smell strong and you would want Kroil soaked into insulation it take your breath away hot. As well as "gentle" tapping. A small piece of wood to fill the handle get some leverage"not too much" and give more ability to push down.Carful grinding as suggested at bottom edge of tightest portion of locking tab at last resort. A vibe saw can be handy with right blade you could ride blade on block of to an exact height, like under cutting trim for flooring. Vibration is also handy to loosen froze parts. One tab or partially maybe all it takes. It's first I've seen that large military looking cap.
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Old 05-17-2022, 05:56 PM   #6
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Thank you 153stars, BillJinOR, 96WideGlide and Twomed.

I am going to try to spray some WD-40 as 153stars suggested and gentle tapping. Also FYI, I've contacted Roger Berke and he said I do not have to push down on giant radiator caps, just use a long screwdriver through the handle to give some leverage.

I will try these suggestions and let you know how it goes.

-Ali
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