O.K. A few things...
Yes...the rad is still leaking...I have not changed the coolant or had the rad repaired yet. It is supposed to go in soon. It is leaking at the lower tranny line recess area. Not inside the fitting...actually around the fittin on the flat area of the rad. tank. Previously it had been leaking from the upper tranny line recess just like the lower...on the flat side of the recess around the fitting. The top one had been repaired 2 times now and is showing a slight sign of leaking but it is so small...the patch is apparently holding for the most part but the lower one is pretty rough now. I am adding about a 1/2 a jug of distilled water every two days now....so yes the leaking is getting bigger.
Brianl703...The Electric fan is a Flex-A-Lite:
http://www.flex-a-lite.com/auto/html/27inch-electric.html
It is grounded to the inside passenger fender near the battery. There is nothing fan related touching the radiator. I have replaced all the connections and double/triple checked my work. It has been on the car for about 3-4 years now. I installed just how they instructed to do it...and the shop has inspected the install and said nothing was out of the ordinary. Could grounding it on the fender be causing it to run through the body and hit the radiator at the A/C condensor brackets? (See below for deatils....)
The Radiator cap is a Rad Cap's with sacrificial anode rated at only 7lbs. Stock rad cap is like 12 lbs I think. I changed it to the lesser 7 lbs cap because the shop wanted to rule out any possible problem with the rad. cap not venting the pressure to the overflow tank.
Possible HEAD GASKET problem idea:
I have had the coolant tested for exhaust gases by two different shops and they found no evidence of exhaust gas in the fluid....and no...I have not had a cylinder pressure check done. I mean...I change my own oil in a pan and I never see anything else but oil coming out. The radiator fluid has always remained green and has NEVER been any other color but green. If I was getting a head gasket leak...wouldn't I have had a change in coolant color?
I also have a sacrifical annode on the end of the radiator car...its called a Rad Cap. It is showing signs of being eaten but it seems to have slowed and remains unchanged right now.
I had been using the Prestone 50/50 pre mix All Makes All Models 150,000 Exteneded service green stuff. I will be trying Zerex if I can find it...if not the rad. shop used Peak Original green. We are not under any circumstances going to put anything with the name Prestone on it back in my car...EVER.
My radiator is completely isolated from the radiator shelf except for the metal trans lines. I have been considering getting a seperate tranny cooler lately. Oh yeah...and I noticed the rad it is touching the metal brackets behind it that are holding the A/C condensor. Because its so wide...it rests against the metal brackets some. Its not a lot but I would be willing to bet that it shouldn't touching it right? I have talked to a few shops and they didn't think that would really make a huge difference. I used a little bit of weather stripping foam to keep it away from the metal on metal contact but it wears through. Could this be the cause?
Again...the shop put the car on a chassis dyno and ran the car like it was on the street and tested the coolant for electricity. They did not find any electricity in the coolant...and what ever little bit they found ended up going under a negitive rating once all the accessories were turned on...example...radio...lights...headlights...brke lights...using the windows. They also checked every part of the wiring harness in the front part of the engine bay by the headlights and around the rad. shelf. They also checked the ABS system...they founf nothing out of the ordinary. They also checked how I installed my fina and it was exactly how Flex-A-Lite instructed to do it.
Look you guys...I am willing to try anything. If this doesn't work I am going to buy a Volkswagon TDI diesel engine'd car and go get a waste veggie oil conversion.