Mark2005
Texas
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Joined: 09/23/2005
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Hello all....did a search and found very little info....has any one replaced the radiator on subject coach?
I have developed a leak and beginning research on possible fixes and weather to attempt myself...Monaco wants $4200 for new radiator....YIKES!!!!
Cummins shop wants 8 hours labor at $130 per
Thanks Mark
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Corkey05
Washington State
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Joined: 06/04/2005
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Contact Source Engineering, they are a reliable source of aftermarket coach radiators with an excellent reputation.
2008 HR Endeavor PDQ - Blazer 4 Down
FMCA F374292
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Yaj
The Milky Way Galaxy (Hartford, WI)
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Joined: 05/07/2009
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I did ours by myself, not to bad a job. I got the radiator here, good, fast service, very helpful finding the right one. and a pretty good price for a quality radiator, copper core w/metal tanks. I drained my system into old food service 5 gal plastic jugs, I did it over a big plastic deep walled pan I got at a farm supply. And I used a engine crane to lift the radiator in and out.
Good Luck!
1996 HR Endeavor LE,Cummins 5.9 230hp, Allison 3060,
Front-Yamaha Enduro, Rear-Honda Helix Geeser Cruiser + 2 bikes,
22ft 1977 Cruiser in tow.
1 DW, 2 kids.
1 old dog, 1 fat cat.
I wasn't thinking this far ahead!
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The Texan
Meridian, Idaho
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Joined: 01/16/2004
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Mark, go to the Monacoer forum and ask this question. There are over 3500 Monaco coach owners on the forum and they know where to get things at a reasonable price. This question was just discussed there in the last week, and the OP found one for under $1000 by asking on the forum.
Bob & Betsy(FishNFanatic) - USN Aviation Ret'd '78 & LEO Ret'd '03 & "Oath Keeper Forever"
'05 HR Endeavor 40PRQ, 400 Cummins-Pulling our '11 Silverado LT, Ex Cab 6.2L NHT 4x4, w/2010 Rzr or 01 V Star in back.
Where the wheels are stopped today
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SacsTC
N. California
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Joined: 12/05/2006
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Check and measure carefully to see if yours is the same size. I know that this will fit an 05 and an 07 Diplomat. Good Luck
2007 Monaco Diplomat 400HP Cummins ISL
Source Engineering RR8R Ride Enhancement Kit
2006 Chevy Silverado 345HP 6.0 TOAD
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SS Slacker
Lino Lakes, MN
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Joined: 04/28/2006
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I am confident that you 04 knight has the same radiator set up as mine(aluminum with the CAC stacked on top and the Tranny cooler external). There were problems with these aluminum radiators craking and leaking between the tubes and the end caps. I was informed by multiple places this problem was not able to be fixed on that aluminum radiator and it would need replacement.
My shop had a radiator shop custom build me a replacement copper/steel radiator that was an exact fit based on the old one and gave me a two year warranty. If this one ever leaks it now can be repaired. Radiator was around $2,400 to be custom built, which was about what Monaco wanted for the replacement Copper/Steel one they offered. My shop was able to do the R&R in much less time as labor was about $400 total and they charge about $125 per hour. All this was about 2-3 years ago.
Dan & Tracy
2 kids ages 9 and 11
2003 HR Neptune 36PBD
300 ISB Cummins/5-Speed
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Diplomat Don
Moorpark, Ca
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Joined: 04/09/2005
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Mark2005.......I replaced mine and did a blow by blow description. Part of the issue with yours and mine is that the CAC sits right on top of the radiator with a little piece of rubber strip. I bought a surplus radiator and charge air cooler from Johnson's . They bought a lot of surplus items from Monaco in Indianna when they went out of business. The items they bought included the rear radiator setup which consisted of the radiator, CAC, complete metal shroud and trans cooler which is a separate item. At the time I bought mine for $650.00. They now realize they're a little more valuable.
These surplus units were suppose to go into 2009 units. They are an exact match for 05 Monacos and up. I'm not sure about your 04. You can take measuremnts to check. These 09 models have a radiator that is an inch shorter. It's shorter because these units have rubber supports on the top and bottom like a car has. Much better design.
It took me a day to remove and a day to assemble. I added new 2" silicon hoses which I bought as premade pieces. There are no custom bends, so I bought lengths with 90 degree bends. My description of how to do it should save you some time. You'll probably need a second person when slipping the CAC back in. You have to worm it in at an angle.
Here is the link to the repair.
PM me if you need more info and we can talk on the phone. The job was fairly easy......just a lot of things to disconnect and reassemble.
Don & Mary 
2005 Monaco Diplomat 36SKT
400 Cummins 
2012 Chevrolet Silverado LTZ CrewCab 4WD
2013 Polaris RZR 800 LE
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Mark2005
Texas
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Joined: 09/23/2005
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Thanks to all that replied!!!! Decided to remove the radiator today and as Diplomat Don and others have said it was not too bad a job. I had some help and it only took about 3 hours.
After removing the radiator I discovered a coke can in the bottom of the shroud that had bounced around and appears to have hit the radiator and created a very small nick in one of the flues...took the CAC and radiator to a shop in Fort Worth that was able to check both and repair if needed ...the CAC was OK and the shop said they could solder the very small nick in the flue ...said the repair would only be guaranteed for 30 years....(smile) total cost will be less than $100.
I still believe I will buy one of the surplus kits from Johnson surplus as the price can't be beat. I spoke with Tim at Johnson today and after our conversation I was confident in the product and was sure that the unit was a perfect fit.
Don, the measurements on the Johnson unit are exactly the same as my coach so it appears that the unit you purchased (the Johnson unit) will work for an 04 Knight as well.
Thanks again to all that responded and provided the encouragement to do this. If all goes as planned I should be able to restart my trip next week. The wife and I were only 50 miles from home when we discovered the leak on Monday so this could have been much worse had we been 2500 miles from home as we expect to be in late June.
Wonder what the odds are of a coke can being able to bounce at just the right time and angle and to bypass the trash guards on the belly of the engine AND clear the mud flap to be sucked up into the engine/radiator cavity ...maybe i should go to Vegas!!!
Mark
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Diplomat Don
Moorpark, Ca
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Joined: 04/09/2005
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Mark.....Once a year when I do my servicing, I clean the radiator and use one of those long finger tools with the three fingers that pop out when you push the plunger. I use it to pull all of the debris out of the two corners at the bottom of the shroud from inside the coach. I meant to cut a notch into the two corners so stuff would fall out, but forgot.
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