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Originally Posted by OregonNed
FWIW I rebuilt mine - non-A/C and got it back together - all good, then I had an intermittent leak like you mentioned. I did not want to pull the Heater box out again! Got to figuring one of the screws to mount the little brackets to hold the Heater core might have somehow punctured the heater core itself, but being intermittent, I kept an eye on it. Turns out the lower hose on the heater must have been loose enough or inefficient so I ended up with two hose clamps to fix the issue. It too would leave just a little coolant on the bottom of the box, and I think it might have migrated inside too, even though the sealing foam was there. Hope you find it!
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I started the truck and let it warm up a little today. As soon as it got warm, it started leaking near that lower heater hose. Although, I still was not able to determine the exact location of the leak(hose connection or something wrong with that tube of the core?). Figured I'd try the obvious and tighten the hose clamp a bit since it looked questionable. If I can motivate myself tomorrow(it's supposed to be 30 degrees colder than today), I'll warm it up again and see what happens. If it still leaks, I'll try a second hose clamp like you suggested before I dive in to the misery of tearing it all apart.