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Bruce
Posted on Friday, March 15, 2002 - 12:23 pm:   Edit Post Delete Post Print Post

Noticed a small hair-line crack beginning to develop on passenger side. Crack is just starting to creep up side, about to overcome curve of topside. I started engine, water was applied, no bubbles are evident.
Several questions for those experienced minds out there:
1)Is this a common occurrence?
2)Is the only solution replacement or can I have this fixed by whatever means?

Since I live down south, water is commonly encountered in the swamps, so I guess a hot long drive followed by submersion was the culprit.
Thanks for your ideas on this.
 

Axel Haakonsen (Axel)
Posted on Friday, March 15, 2002 - 03:44 pm:   Edit Post Delete Post Print Post

It's fairly common. Sometimes you can weld it, but ultimately you will probably have to replace it.
 

Paul T. Schram (Paulschram)
Posted on Friday, March 15, 2002 - 04:25 pm:   Edit Post Delete Post Print Post

If it isn't leaking yet, try drilling a very tiny hole at the end of the crack. Sometimes, this technique will reduce the stress that would otherwise cause the crack to propagate further. Try not to drill all the way through-obviously.

Paul
 

Curt
Posted on Friday, March 15, 2002 - 04:29 pm:   Edit Post Delete Post Print Post

Just fix it. (You will have to sooner or later) I have had the same problem on both of my D1's. Any repair shop can do it...no reason to go to dealer. It was under $200 if I remember correctly.
 

Dean Brown (Deanbrown3d)
Posted on Saturday, March 16, 2002 - 09:00 am:   Edit Post Delete Post Print Post

Curt - what's the fix? Just weld over the crack or something?
 

Kyle
Posted on Saturday, March 16, 2002 - 09:19 am:   Edit Post Delete Post Print Post

Drill a hole at each end of the crack , take a grinder on its end or a cut off tool and make a trough out of the crack. Fill said trough with weld and be done with it.


Kyle
 

Mike D1
Posted on Saturday, March 16, 2002 - 09:51 am:   Edit Post Delete Post Print Post

Yes it's common. I replaced both sides on my 97. I say replace it. I got the new ones from Atlantic British.
 

jeb
Posted on Saturday, March 16, 2002 - 05:17 pm:   Edit Post Delete Post Print Post

it is common on any offroad vehicle that encounters water. once it leaks, don't ride it too long or you'll burn an exhaust valve. i had a ford that couldn't keep manifolds so i left one cracked for a while. never had a problem, but i would not recommend that. i was poor at the time and had no choice. if you are going to replace it, what about putting on headers and a new cat back system ;) just a thought from a tennessee redneck that like to hear the rumbling. if only my wife would let me do it to our Disco II
oh well, it's mine after it's paid off. ;}
 

Scott Tschantz (Scott)
Posted on Saturday, March 16, 2002 - 10:11 pm:   Edit Post Delete Post Print Post

I replaced mine last year I got my part from Nathan at Discount Rovers I cant remember the exact price but it was under 160.00

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