[campstove]

Hi all,
I have a 2005 Chevy Astro AWD Cargo Van with 175k miles which I've really loved and have put a lot of money into keeping going over the years. New transmission at 120k, new radiator, fuel pump, starter, catalytic converter (yup), brake and fuel lines, etc, etc. I paid $1.5k last summer trying to address a cooling problem that now appears to be a head gasket leak that is causing overheating. Mechanic says it'll be $1800-2k to fix correctly. There's no water in the oil and the van still runs well until it begins to overheat on longer drives or any sort of climbing.

This van is from Wisconsin (now in rural CA (it passed smog here this summer) and has some rust, but I'm trying to decide if I should keep going with it or give up at this point. I guess I ultimately need a cargo van that will be reliable on 200 mile round trip commutes 1-2 times per month.

What do you guys think? Would you all keep going further with a van like this? Do you think it could still be a reliable vehicle worthy of investing more dough into or should I cut my losses and move on? Thanks for your thoughts...

Some have said that this might be a good candidate for quick fix head gasket sealant, since it seems to be a small leak but I'm on the fence about that too (read the recommendation below from the user mMusicman which seems pretty likely in my instance). Hmm...

The problem you describe sounds like it could be a "possible" hair-line head gasket leak. At higher speeds, the combustion pressures from the cylinder leak into the cooling system... forcing possible air pockets around the cylinders and pressurizing the cooling system. These small air pockets or bubbles can cause higher than normal cylinder wall temperatures, which creates a small chain-reaction. This added pressure forces more than a normal amount of coolant back into the recovery tank, meaning less effective coolant in the cooling system. Add hot air pockets and less coolant, and you start to run hot. Extra typical of more output at highway speeds. Of course, once the system cools down after sitting, it pulls the coolant (from the recovery) back into the cooling system. By the way.. they apparently do make effective chemical head gasket sealing solutions for this... from people I've talked to that have used them. While considered a temporary fix... some say they have gone for years. You can read the reviews on the various available products.

This is just a "possible" scenario. I've seen it before. Not all blown head gaskets blow coolant into the oil. Leaks can develop between cylinders, as well as between cylinders and coolant passages... all kinds of places.. and sometimes they are tiny.

 

[bryancraftyhands]

I'm more about repair and restore than throw away. Spend your 2k on your head gasket, and you know what you have for 2k, including all your past work, when it will likely need done again, and usually a warranty on the labor by the shop that does it if you are using a shop.
Buy another used vehicle, and you might still have 2k or more worth of repairs needed, and have no idea until they come up.
Buy a new vehicle, might still have issues, but you have the warranty, and the payments.

 

[HotBananas]

Wow! I seem to be having a similar issue. I've owned my van for about a year and a half and it currently as 118k miles. I took it to the mechanic as one of the lines to the cooler system was dripping.. Which at the time I was convinced it was either power steering or transmission. Anyways, My coolant keeps getting a little muddy so I'm gonna get a back-flush, and then maybe have to replace my headers within a year or so. I'm imagining at least.. all speculation. My van hasn't been overheating necessarily, but on 70mi. drives over the coastal range in Oregon I do find that I will get a rapid misfire code occasionally. I'm in my mechanics hands at this point lol hahah

 

[medicman]

I'm not of the philosophy of "the repair costs more than getting another vehicle" when the next vehicle could have the same issue or worse. I've already come to terms with the fact that I'll replace an engine or trans on my van, and run it until it rusts apart.

 

[yoshmyster]

Your story is the definition of "in for a penny, in for a pound". First how bad is the rust?

So the mechanic's not going to cut you a break?

If you're going to fix, fix it right. Also where are you going to find a $2000 ride today that isn't a basket case?

 

[bryancraftyhands]

When it rusts so bad, the chassis no longer holds the engine and transmission. We can always rebuild the rusted body with sheet metal, and wood!
Really, I'm sure we've all seen it done. i know I have.

 

[markmitch]

The first thought I had after reading your post was how much rust do you have? Are there holes in the sheet metal?

 

[campstove]

The first thought I had after reading your post was how much rust do you have? Are there holes in the sheet metal?

Here are a few pictures of the rust situation of the vehicle. From the untrained eye, it appears like the area around the radiator support is still ok. What do you all think?? Thanks!

 

[campstove]

I'm more about repair and restore than throw away. Spend your 2k on your head gasket, and you know what you have for 2k, including all your past work, when it will likely need done again, and usually a warranty on the labor by the shop that does it if you are using a shop.
Buy another used vehicle, and you might still have 2k or more worth of repairs needed, and have no idea until they come up.
Buy a new vehicle, might still have issues, but you have the warranty, and the payments.

Thanks Bryan. I think you're right...

 

[campstove]

Wow! I seem to be having a similar issue. I've owned my van for about a year and a half and it currently as 118k miles. I took it to the mechanic as one of the lines to the cooler system was dripping.. Which at the time I was convinced it was either power steering or transmission. Anyways, My coolant keeps getting a little muddy so I'm gonna get a back-flush, and then maybe have to replace my headers within a year or so. I'm imagining at least.. all speculation. My van hasn't been overheating necessarily, but on 70mi. drives over the coastal range in Oregon I do find that I will get a rapid misfire code occasionally. I'm in my mechanics hands at this point lol hahah

Good luck with it... Sounds like it has amazingly low miles still...

 

[campstove]

Your story is the definition of "in for a penny, in for a pound". First how bad is the rust?

So the mechanic's not going to cut you a break?

If you're going to fix, fix it right. Also where are you going to find a $2000 ride today that isn't a basket case?

Yeah, I agree with your logic here. I wonder if I should have a more complete rebuild done while they are there doing the header gaskets. I read somewhere that a rebuild was about 15 hrs for a shop, which isn't all that much different from what I'm getting quoted just to do the head gasket job. Thoughts?

 

[campstove]

Yeah, I agree with your logic here. I wonder if I should have a more complete rebuild done while they are there doing the header gaskets. I read somewhere that a rebuild was about 15 hrs for a shop, which isn't all that much different from what I'm getting quoted just to do the head gasket job. Thoughts?

I posted some photos of the rust in another response down below. Check it out and let me know what you think if you want. Thanks!

 

[bryancraftyhands]

Your rust doesn't look all that bad either actually. Really just pay close attention to critical support. Fame, supports, pillars, along those lines. the rest is body and really cosmetic or weather proofing.
That shot of your rocker at the transfer case looks to be the worst to worry about, and yet, the supports themselves although not pretty, don't look like they are close to failing from here.

 

[Mmusicman]

Is it worth 2K to fix?
How about.. is it worth $60 to fix?
Would that be worth a try?

I successfully FIXED my head-gasket leak last year using "Blue Devil Head Gasket Sealer". The product comes with high reviews and success rates, several car pros actually recommended it to me. The product claims the fix is permanent. Last year the fix worked for me. Many long trips (several out of state) tens of thousands of daily use miles, and it's still fixed for me.

I normally believe in "fixing it right".. but unfortunately head gasket replacement in these Astro vans is a huge (and for some expensive) job. I throw a $60 bottle of product in my radiator and get the same results, I can live with that. If I ever pull the engine, that's when it would get fixed, or replaced.

To me it's worth a try.
If you do, make sure it's the expensive stuff in the yellow bottle.. and follow directions.
The process requires full flushing out coolant and can be a little involved if you are inexperienced.

 

[campstove]

Here are a few more from today when I removed the front grill and lights. It definitely revealed some rust issues, but I'm curious what you all think after seeing this... There are a number of compatible Astro's in the local pick n' pull yard that I could possibly pull a replacement radiator core support from, but I have little idea of how involved that repair might be (does the engine have to be pulled or anything?). Do you think this is bad enough that it is dangerous or problematic in the near future? The van is currently in a very dry desert valley. I don't see any sag or anything yet, but there is definitely rot/rust there from life in the rust belt. Thanks for any feedback you can offer...

Your rust doesn't look all that bad either actually. Really just pay close attention to critical support. Fame, supports, pillars, along those lines. the rest is body and really cosmetic or weather proofing.
That shot of your rocker at the transfer case looks to be the worst to worry about, and yet, the supports themselves although not pretty, don't look like they are close to failing from here.

Here are a few more from today when I removed the front grill and lights. It definitely revealed some rot /

 

[campstove]

Is it worth 2K to fix?
How about.. is it worth $60 to fix?
Would that be worth a try?

I successfully FIXED my head-gasket leak last year using "Blue Devil Head Gasket Sealer". The product comes with high reviews and success rates, several car pros actually recommended it to me. The product claims the fix is permanent. Last year the fix worked for me. Many long trips (several out of state) tens of thousands of daily use miles, and it's still fixed for me.

I normally believe in "fixing it right".. but unfortunately head gasket replacement in these Astro vans is a huge (and for some expensive) job. I throw a $60 bottle of product in my radiator and get the same results, I can live with that. If I ever pull the engine, that's when it would get fixed, or replaced.

To me it's worth a try.
If you do, make sure it's the expensive stuff in the yellow bottle.. and follow directions.
The process requires full flushing out coolant and can be a little involved if you are inexperienced.

View attachment 287064

I'm feeling pretty tempted to go this route...

 

[bryancraftyhands]

I see your extra. My philosophy on that part of the job is if it isn't broke enough to cause some kind of fail, don't try to fix it.
However, if you decide to do the gasket and are going to be down a while, then why not while you are at it.

 

[Sailing_Faith]

Just scanning this thread, I am kind of surprised that no one seems to have told him that his mechanic is very likely wrong and the diagnosis may be incorrect.
Lower intake manifold gasket failure is much more common then head gaskets….

 

[jn.mitchell59]

Hi all,
I have a 2005 Chevy Astro AWD Cargo Van with 175k miles which I've really loved and have put a lot of money into keeping going over the years. New transmission at 120k, new radiator, fuel pump, starter, catalytic converter (yup), brake and fuel lines, etc, etc. I paid $1.5k last summer trying to address a cooling problem that now appears to be a head gasket leak that is causing overheating. Mechanic says it'll be $1800-2k to fix correctly. There's no water in the oil and the van still runs well until it begins to overheat on longer drives or any sort of climbing.

This van is from Wisconsin (now in rural CA (it passed smog here this summer) and has some rust, but I'm trying to decide if I should keep going with it or give up at this point. I guess I ultimately need a cargo van that will be reliable on 200 mile round trip commutes 1-2 times per month.

What do you guys think? Would you all keep going further with a van like this? Do you think it could still be a reliable vehicle worthy of investing more dough into or should I cut my losses and move on? Thanks for your thoughts...

Some have said that this might be a good candidate for quick fix head gasket sealant, since it seems to be a small leak but I'm on the fence about that too (read the recommendation below from the user mMusicman which seems pretty likely in my instance). Hmm...




View attachment 287016

Hows about taking the "possible" completely out of the equation" A cooling system combustion-gas test will tell you without question if a head gasket is leaking. Also, an eroded or even loose-fitting impeller on the waterpump will cause the same thing. -Best to take the guesswork out of a major repair, and just go for the throat, so to speak.

 

[jn.mitchell59]

Just scanning this thread, I am kind of surprised that no one seems to have told him that his mechanic is very likely wrong and the diagnosis may be incorrect.
Lower intake manifold gasket failure is much more common then head gaskets….

Probably because while the lower intake gskts do fail, when they do, it causes coolant in the oil, which in this case isn't happening. Plus, that wouldn't cause compression gases into the cooling system.