I am putting this here for future reference.

I know this is a loaded subject, fix the leaking throttle heater body... or do a bypass. I live in Canada where the weather is much colder. I chose to go with the former as a pre-caution.

1) There is the usual gasket change option. However, the problem usually re-appears a few years later as the factory throttle heater body base is prone to warpage. Kits usually run in the $20 to $50 range.

2) Another know option is to change to the solid bronze body version offered by Falconwerks. But this is a pricey option at $200+:
https://www.jewellamberoil.com/sales...roducts_id=303

3) I have just learnt of a new (Canadian) supplier who is offering another option at $75. This supplier provides a thicker aluminum body to prevent the warpage issue:
https://www.sportscarcentre.ca/MGM000010K?mid=948

I am NOT affliated with any of the suppliers. I used the Falconwerks version a couple of years ago as I got tired of changing gaskets every year. Still holding up well. I would certainly have tried the cheaper option #3 if it was available back then. Just thought I pass on this info to this forum. Would love to hear from anyone who has tried option #3.

Just thought I share this info.

 

As bad *** as #2 is, I think for as often as these fail (in my anecdotal experience, once every 75,000 miles on one D2 and once every 162,000 miles on my other), I think I'll keep replacing as needed. Remember, one issue is Dexcool. It eats and seals, swells them, and probably leads to the warping issue.

 

Option #4 - cost ~$20.

One middle - https://www.acehardware.com/departme...ttings/4338570
Two elbows - https://www.acehardware.com/departme...ectors/4504684
Three hoseclamps - two for hoses and one to secure to old throttle body heater for thermal transfer

Wanted to have a hybrid solution that would solve the leak and not need routine replacement. Testing on my '99 D2. Keeps coolant flow and allows some of the heat to get onto the throttle body plate. Apologies in advance for the poor pics. I could update when I put one on my '00 D2.

I've been thinking up a way to have a similar setup with a better connection to the throttle body, but with the topic, sharing my early research.

 

Someone on another forum spent the $$$ on that custom TBH Plate from Falconworks & my 2 year old daughter could have made a better piece of hardware out of her Mega blocks!

 

I did the TBH when I did my headgaskets, and resurface the TB. If me memory serves it was 180 and 220 grit straight, then turning 90 degrees. Got it really flat, and created a better mating surface.

We’re moving back to MN from Chicago next month so I am glad I did it.

I don’t know I would splurge for the Falconwerks solution. It’s not a hard job to swap out the TBH, but I would try the 75 likely. Thanks for posting.

 

hey, I have a toddler, we have megablocks, let’s start a business!