Need Quick Expert Advice on Surge Tank, 02 Journey 39QD

GG1 · 12-25-2009, 01:35 PM

As usual last minute problems arise,,,,We had planned to start for the 4 month excursion South on Sunday Dec 27th but I noticed what looks like a few hairline cracks just above the center on the clear plastic anti freeze tank, I think they call it a surge tank. Actually they look like surface imperfections and nothing is leaking. My question is how do you remove the shroud that fits between the top of the radiator and the top of the compartment. I can find a few bolts on the left side but I find nothing on the right from the outside looking in. I have found good info on the forum about the tank replacement but nothing about removing the shroud. Any help would be appreciated.

Chuck 1935 · 12-26-2009, 04:42 PM

Just finished doing the surge tank replacement 10 minutes ago and it's a snap if you follow the guidelines that you found. As far as the shroud goes, I have a 2004 Itasca Meridian with the 330 Cat so it should be about the same as yours. There is a two piece shroud on the rear. One held on by 3 screws and the larger shroud that has three bolts. One on the left by the trans dip stick, one towards the middle and a blind one all the way on the right on the side of the tank. All you can see is the head of the bolt and when you try and take it out the nut turns as well. As was suggested, after removing the 2 bolts that are accessable you then take a sawzall to the surge tank and cut the plastic tab so that you can access the blind nut. When re assembling it use U shaped spring nuts on the blind side so that you don't have to fight the nuts. One spring nut goes on the tank on the rear most attachment the other goes on the metal bracket at the forward attachment point. You do have to remove the bed plywwod cover (4 screws). It is an easy job. My tank was crazed like yours and it finally developed a leak. I tried JB Weld and it kept popping loose. Just replace the tank,$107.00

Chuck 1935 · 12-26-2009, 05:55 PM

Also type in "Replaced surge tank on 330 cat Journey" in Search, It is very comprehensive.

Zimectrin · 12-30-2009, 10:14 PM

I am going to have to join the party as my surge tank is crazed and leaking. Weld lasted one trip and now it's too cold to play so will wait till Spring.

My question is: What did you do to prevent this from happening again?

Seems to me this should not be happening. A real pain as well as expensive.

Chuck 1935 · 12-31-2009, 08:56 AM

You can paint the exposed part of the tank with a spray can or mount a flap over the tank to prevent the sun from killing the plastic. You probably have a plastic oil tank back there that should also be protected the same way. Painting any exposed plastic will prevent the UV rays from killing it.

Zimectrin · 12-31-2009, 09:25 AM

Which color is best? I would think white.

Zimectrin · 01-09-2010, 03:08 PM

Where do I get the part number for the surge tank?

Chuck 1935 · 01-09-2010, 04:23 PM

Call your local Freightliner dealer and give them the last 6 digits of the vin number and they can get you the correct part number. The part itself costs about $107. As for color I just took a black piece of garden edging and screwed it to the support piece just under the tank. In order to see the tank coolent level or add coolent all I have to do is bend down the plastic flap. If you paint it just mask off a little strip so that you can check the coolent level or else you might be able to see the level from the side. Going with black lets it blend into the background.