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Discussion Starter · #1 ·
Hi guys, I have not been on here for a while but have a problem which I think you should all be aware of.I tried to twist off my radiator cap yesterday and the four plastic lugs snapped off leaving a section of the plug stuck in the expansion tank. I have ordered a new cap from Amazon and some silicone grease as apparently the problem is the rubber gets hot and expands and then when you try to twist the cap off the workings are stuck tight hence the four plastic lugs snapping off on the underside of the top of the cap.

This is just a heads up so that you don,t get the same thing happen to you. I would suggest trying to gently undo your cap,then put a smearing of silicon grease around the inside and then put back on but don,t over tighten it.
Has anyone on here had the same problem ? I know this is a known fault as I have had a good look on the internet and looked at reviews on Amazon etc . Apparently the part that is stuck in the tank is a real bugger to get out.
 

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I had exactly the same thing happen.And you're right, it's a right pig to remove the thing. I had several attempts to get the thing out and at one stage thought i'd need a new expansion tank.I'm afraid only brute force with a couple of screwdrivers gotit out. And I also did grease the rubber seals on the new cap.
I now remove the cap every few weeks to ensure it doesn't get stuck again.
 

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Discussion Starter · #5 ·
pegleg said:
I had exactly the same thing happen.And you're right, it's a right pig to remove the thing. I had several attempts to get the thing out and at one stage thought i'd need a new expansion tank.I'm afraid only brute force with a couple of screwdrivers gotit out. And I also did grease the rubber seals on the new cap.
I now remove the cap every few weeks to ensure it doesn't get stuck again.
I could not get mine out so went to the Ford garage. They said they have done quite a few so it is a known problem. I think it,s a design fault as the four plastic lugs are not strong enough and snap easily. I have ordered a new cap from Amazon and then the Ford mechanic will do it for me as I don,t want to risk breaking the expansion tank. I will also check it every month now mate.
 

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I had exactly the same thing happen.And you're right, it's a right pig to remove the thing. I had several attempts to get the thing out and at one stage thought i'd need a new expansion tank.I'm afraid only brute force with a couple of screwdrivers gotit out. And I also did grease the rubber seals on the new cap.
I now remove the cap every few weeks to ensure it doesn't get stuck again.
Hi PegLeg- I've had exactly this problem. I've been attempting to remove the black snapped off section that seems to be well and truly wedged into the top section of the neck of the expansion coolant tank. Exactly how do you manage to remove yours. A step by step guide would be most grateful received.
Thanks, Mark
 

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Hi Mark,
I used two flat blade screwdrivers and ended up distorting the shape of the expansion tank neck in order to apply enough leverage to get the thing out. I was close to damaging the expansion tank. It really is brute force I’m afraid. I almost gave up!
 

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Hi Mark,
I used two flat blade screwdrivers and ended up distorting the shape of the expansion tank neck in order to apply enough leverage to get the thing out. I was close to damaging the expansion tank. It really is brute force I’m afraid. I almost gave up!
Many, many thanks for your reply and good advice. Most appreciated 👍
 

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Hi Mark,
I used two flat blade screwdrivers and ended up distorting the shape of the expansion tank neck in order to apply enough leverage to get the thing out. I was close to damaging the expansion tank. It really is brute force I’m afraid. I almost gave up!
Hi again PegLeg- I've now managed to removed my broken cap using a few squirts of silicon spray and brute force and 2 flat blade screw drivers as you'd suggested. After about 10 minutes and carefully applying a good degree of force, the cap finally came free! Thanks for your help and tips and to other members who posted their useful tips as well. And yes, very poor part from Ford. Requires a redesign!
 

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When you get a new one, smear some glycerine around the rubber seals to prevent the same happening again.
Glycerine is really good for rubber; smear it on door seals to prevent freezing; never use Vaseline as it contains petroleum which makes rubber swell.
You can find glycerine in any supermarket in the baking section at around a quid a bottle.
 
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