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Coolant overflow bubbles over, but... not head gasket?

Discussion in '1st Gen Tundras (2000-2006)' started by paul85, Sep 11, 2025 at 6:34 PM.

  1. Sep 11, 2025 at 6:34 PM
    #1
    paul85

    paul85 [OP] New Member

    Joined:
    Aug 9, 2021
    Member:
    #66530
    Messages:
    19
    Gender:
    Male
    Lawrence, KS
    Vehicle:
    2006 Tundra Double Cab 2WD 4.7 liter
    In my previous thread, I bought a 2006 tundra with 298k miles on it with a broken timing belt. I put a new timing kit on it and have been driving the truck around. Here's the new issue..
    Every time I go somewhere and get out of the truck, I smell coolant. There's no coolant on the pavement or on the engine, nor any coolant coming out of the exhaust. I think, the smell is coming from the overflow, and if I drive it prolonged periods of time, 20+ minutes, The overflow will.. overflow, and slowly leak out the overflow. So, I thought.. crap, headgasket is blown. I did a pressure test, and it will not hold pressure. I took the intake manifold off, replaced an O ring in the tube that goes under the intake to the rear of the engine, and it holds pressure a little better, but still leaks down in 30 seconds. I do not see coolant ANYWHERE though, so figured its a headgasket for sure. I checked in the cylinders, checked under the vehicle, checked the freeze plugs, checked each connection, nothing is leaking, nothing is seeping, no coolant visible anywhere.
    I bought one of those kits on Amazon and performed the test to check for combustion gases in the coolant. The truck ran for 20 minutes, and I revved the engine up to 3000 rpms several times for a minute each time. The test came back no combustion gases present. It stayed blue, the same exact color I started with. In that time, the coolant in the overflow tank went up about 1/2-3/4 inch.

    Every time I start the truck, it starts right up, no smoke, no coolant smell.

    What is the deal? Why is my system building pressure but no coolant gasses present? I'm going to run the test again tomorrow, but am mystified as to what is going on. I might go get a dye kit from Autozone and put that in the coolant and check it with a black light, but I'm at a loss as to where this coolant is going, why my system is pressurizing, yet, no gas present in the coolant.
     
  2. Sep 11, 2025 at 6:45 PM
    #2
    assassin10000

    assassin10000 New Member

    Joined:
    Oct 27, 2020
    Member:
    #54157
    Messages:
    2,310
    First Name:
    Andrew
    Northern CA
    Vehicle:
    '05 SR5 AC 2wd
    Remote start alarm Removed keyless entry piezo Qi phone charger & dash mount Subaru underseat subwoofer Hopkins Easylift Steering wheel audio controls No-tenna mod 3/4 adhesive anti-rattle shim D/S door
    Pressure test the radiator cap?
     
  3. Sep 11, 2025 at 6:50 PM
    #3
    paul85

    paul85 [OP] New Member

    Joined:
    Aug 9, 2021
    Member:
    #66530
    Messages:
    19
    Gender:
    Male
    Lawrence, KS
    Vehicle:
    2006 Tundra Double Cab 2WD 4.7 liter
    I was thinking I would go buy a new rad cap tomorrow, but the pressure tester I used clamps down right where the rad cap goes and it still leaked. Maybe there's a small crack in the top of the radiator neck or something, but I sprayed soapy wooter on everything around there and found no bubbles coming from anywhere when I pumped the pressure up.
     
  4. Sep 13, 2025 at 6:53 PM
    #4
    bfunke

    bfunke Tundra Curmudgeon

    Joined:
    Oct 13, 2019
    Member:
    #37321
    Messages:
    2,741
    Gender:
    Male
    First Name:
    Bryan
    South Carolina
    Vehicle:
    2018 SR-5 CM 5.7, 2000 SR-5 AC 4.7L
    Might get a new thermostat and be sure to put jiggle valve up at 12:00 position. Post some pics of radiator, hoses and crossover pipe areas.
     
  5. Sep 14, 2025 at 2:19 PM
    #5
    bing5

    bing5 Long member

    Joined:
    Oct 23, 2024
    Member:
    #124729
    Messages:
    209
    Gender:
    Male
    New Mexico
    Vehicle:
    2004 Double Cab. 270k+
    Like she came out of the factory.
    Heater core?
     

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