Dorman 10691 Radiator Overflow Tube Repair Kit

Received a radiator with a broken overflow from an online supplier and this worked great to fix it. Had to drill the hole bigger to get this to go in but once I got it to the right size, I got it put together and tested and no more leaks or issues

Could not use the product its too big and the manufacturer doesnt respond to questions to find out before you buy

Works awesome. Saved me from buying a new radiator. Great product!

TLDR. I installed this into my Nissan Titan 2004 and it leaked. Then I removed it and made sure to file down the outer surface of the radiator neck so the o-ring could be seated properly. Seems to be working fine now.The kit comes with 3 pieces : inner nozzle (OD=5/16"; threads 23/64"); outer nozzle (OD=3/8"), and o-ring (5/16"). The inner nozzle fits inside the radiator neck, then place the O-ring, and screw down the outer nozzle. If the inner nozzle is too long for your radiator neck, you may have to shorten it by cutting it with a dremel or hacksaw. It fits fine in the Titan.Installation. Place a shop rag in the radiator neck to prevent pieces from dropping into the radiator. File down the broken nipple. Enlarge the old hole. When drilling on the Titan remove the plastic engine cover to get a better angle. Carefully enlarge the hole with a 5/16" bit, and then a 3/8" bit (or 23/64"). On the Titan, ideally, you should enlarge the hole by making it straight and centered slightly above the old hole center. However, I ended up just drilling into the old hole and angling the new hole up slightly toward the radiator cap. This unfortunately put a gap in the bottom of the new hole, so the first time I installed it, it leaked at this gap. Then I used a flat file to more aggressively file the outside of the new hole so it was completely flat so that the O-ring would seat flush on it. I checked it by placing the file flat on the hole and used a bright flashlight to check that light did not leak through the bottom gap. Someone mentioned using two o-rings, inside and outside, but I tried that with another similar o-ring I had but the extra thickness made it difficult to tighten. Someone else mentioned using a larger O-ring and I happened to have a pack of thicker 9/16" OD x 5/16" x 1/8" o-rings from home depot. These o-rings were thicker than what came with the kit. I'm not sure if the smaller o-ring that came with the kit was sufficient, but I ended up using just one of the thicker o-rings. The instructions say to screw down the outer nozzle finger tight. Then use a wrench to turn it 1/2 turn. If it leaks, turn it 1/4 turn more, but don't crush the o-ring.In my install on the Titan, the new nozzle points at a downward angle. The inner nozzle "wings" are kind of bent at an angle. On the Titan, the radiator cap is just flat and doesn't have an external spring, so I did not have to worry about any clearances or blocking of the cap spring like on some other vehicles.The OEM Titan overflow hose is 5/16" ID, approximately 33". I tried to re-use the OEM 5/16" hose, but it fit very tight and was a pain to take it off again. I replaced it with 32" of 3/8" ID heater hose ($6 Gates Safety Stripe 28409 / 3270) cut from local auto parts store. I re-used the old 5/16" spring clamp on the coolant overflow tank, but used a new hose clamp at this new connection because the old spring clamp seemed a little tight on the new 3/8" nipple.Started the Titan again and no leak. Refilled some of the coolant lost from the first time it leaked. Then re-started and got it up to temperature. So far it's holding fine.FYI: I broke the original overflow nipple while leaning over the engine to change the spark plugs. Just goes to show you, mess with one thing, but break another.... I could just install a new radiator which I think would take me about 2 or 3 hours (since I already changed the condenser and it's messy but not too difficult) and I've thought about putting in a better radiator anyway. But this fix was just easier and cheaper for now. And since I already bypassed the fluid-fluid cooler (transmission oil to radiator), I'm not too worried about ruining my transmission if the radiator cracks (strawberry milkshake of death). If this fix starts to leak, I might try patching it with jb weld, but I'll probably just get a new radiator. But I feel like this is a mechanically solid repair.

Works perfectly on 2006 nissan titan. I used my dremel to grind the area flat and my drill with a 3/8 drill bit. No JB weld or any other glue used. Job took less than 40 minutes.