I don't suppose there's an easy way to replace that dumb little hose without removing the water pump or the entire thermostat housing? Mine was leaking badly, but I'm afraid I've gotten myself into a bigger problem than I started with trying to get at the hose

Edit: This is my 1985 300D; I have drained the coolant already.

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http://webwench.net/albums/new83-300...1700.thumb.jpg
1983 300D-T
348,000 miles

Remove top radiator hose from thermostat housing.
Loosen 2 clamps on the little hose.
Remove lower radiator from thermostat housing.
Remove the 2 bolts that hold that housing to the head.
(Get a new gasket)
Replace the hose.
Install in reverse order.
Have some emory cloth or sand paper to clean up the oxidation on the hose connections.
Not hard to do.

Edit: put Never Seeze(sp) on the bolts when installing.

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1985 300D California w/cat. (257,000 + Miles)
1980 300SD (208,000 + Miles)

I guess that's not so bad... good excuse to replace a few other hoses too.

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http://webwench.net/albums/new83-300...1700.thumb.jpg
1983 300D-T
348,000 miles

I have personally done this also, it it simple.

I just cut the hose off, had an auto parts store match it, then took off the thermostat housing and installed it... not more leaks!

I have to replace this short hose on my 1985 diesel. I would like to know the ID before starting. I tried to use some of my high school geometry by wrapping a piece of string around the themostat housing to hose connection, then measuring the length. Got 6+ inches. Divided by Pi (3.14) and got 2 inches for the ID. However when searching this site someone indicated the ID is 1-1/2 (38mm). I couldn't find this part listed for sale at Fastlane. Does anyone know what this part is called. What is the gasket called?

you cant get this hose at fastlane, I talked to phil about it... the only way he could do it was if he sold you a meter of the stuff which I guess is great if you have the extra dough.. if not.. just run to your local auto parts store with the hose and get the cheapest one that matches the diameter. Then cut it to length.

That gasket can be found here> http://catalog.eautopartscatalog.com/mercedesshop/sophio/wizard.jsp?partner=mercedesshop&clientid=catalog.mercedesshop&baseurl=http://catalog.peachparts.com/&cookieid=1QV18Z9X81RS18WWQF&year=1985&make=MB&model=300-SD-002&category=G&part=Thermostat+Housing+Gskt.

but often that hose will loosten its clamps and leak that way,

be sure to check them before going to all that.

tom w

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[SIGPIC] Diesel loving autocrossing grandpa Architect. 08 Dodge 3/4 ton with Cummins & six speed; I have had about 35 benzes. I have a 39 Studebaker Coupe Express pickup in which I have had installed a 617 turbo and a five speed manual.[SIGPIC]

..I also have a 427 Cobra replica with an aluminum chassis.

It is called the bypass hose. The I.D. is 42mm. I just bought one from my local MB dealer. They sell it by the inch. Cost $4.60 for two inches. At that price, its not worth trying to find a substitute.
What is the thermostat housing gasket called? Let's see.......thinking back to my high school english class.....why call it anything else?

New hose clamps did make a difference. The old ones were corroded and just wouldn't tighten enough. But the end of the hose seems spongy and the antifreeze seems to permeate right through the hose, so thanks all, now I have all the info I need.