Cracked expansion tank - is it common?

[Nobbles]

In April when summer looked to have arrived, I noticed on one occasion a tiny puddle of liquid, car had just been washed so I thought to keep an eye on it. But then the cold spell came and nothing. It has just had its major service with belts and coil packs and no notice of coolant leak, but it was 10° outside. Now the summer is here I have noticed the small puddle return. Long story short I was at my specialist today and with his special camera he says it is the expansion tank that has a tiny split and with the heat it is expanding much more and then leaking. Is this common and of course what is the going price for this replacement. Whilst this is being done, coolant change etc is there anything else to do at the same time?

[Hilux2400]

If it's a 996 do the low level coolant sensor, new coolant reservoir cap, Air Oil Separator (AOS), the plastic oil filler tube and get the alternator checked over. Also check the small dia. alloy coolant vent return pipe (mine was rubbing against the bodywork). Replace as many coolant clips as you can get to with worm drive clips. And while you are at it put on a new serpentine belt. Some might say also replace the water pump as the vanes don't last that long in view of the effort this pump has to dish out in circulating such a large volume of coolant.

[Beety]

Yes very common, its best to lower the engine a bit as it makes it so much easier to change it !

[Nobbles]

The belt was done as part of the major service it as just had. So reading up more I should at least do the expansion tank, coolant sensor and cap. Water pump seems excessive - are they a common failure for a 996tt? I refuse to pay for a water pump as preventative maintenance unless it is really advisable. the bloody car will be new by the time I have finished.

[jsmjsm]

My tank split at xmas and I had the opc repair it for £400. They didnt do anything else but the tank and its fine.

[jonsmiff]

my cayenne turbo s did this, just changed the tank and did a coolant flush, all good, the replacement tank was a superceded part as the old ones were splitting frequently apparently.

[Nobbles]

Any ideas on price? I am over in France so it is typically UK price + 20% .... which I didn't plan into my man maths....

[Hilux2400]

I think the up to date tank is about £90 and the AOS about £50, if I recall. The labour is about 4 hours minimum. I know replacing some of the other things might seem OTT, but the AOS failure does happen at about 50K from what I read elsewhere. That's why I did mine at the same time and for just a small amount of extra work, on the same side of the engine, it's worth it.

Also the AOS replacement results in a lot of coolant loss and as you will be replacing the coolant, when doing the header tank, it seems a shame not to make best use of the opportunity.