Join Date: Feb 2014
Location: Gainesville, Fl.
Vehicle: 99 Dakota
Modifications: Quad Cab swap, Cummins swap, Solid axle swap
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A few years ago, I was losing coolant and couldn't track it down. I would sometimes see a wet spot or evidence of a wet stain around the end of the upper rad hose where it attached to the radiator. I was certain that there was coolant leaking out of the end of the hose and tightened the clamp as much as I dared. Still kept losing coolant. Not much, but noticeable over time. On a whim, after a drive, I opened up the hood and wiggled the upper hose and coolant bubbled out of the plastic radiator tank, near the hose….. I mean right thru the plastic! Well upon really close inspection, there was a very small crack in the tank and it was so small that I wasn't able to see it. Wiggling the hose opened the crack, it was so small that water sweated out of the crack and rapidly evaporated leaving the stain. It was so small a crack that it might not have shown with a pressure test…at least in a few minutes
I know you said you replaced the radiator, but make sure it is absolutely sealed. You could try adding some dye to the system, then see if you can find a possible leak by using a florescent light to spot any dye outside the system.