240 1993 Broken upper radiator outlet

240Dad · Post by **240Dad** » 25 Oct 2009, 16:56

Recently I had an overheating problem and replaced the thermostat in the air box, cleaned the MAF wires with an aerosol made for cleaning them. I also replaced the circuit board in the instrument cluster with a jumper wire so that the coolant temp gauge would work correctly. Everything turned out well. Then the next thing to work on came up unexpectantly.

While I was taking out the air box I barely touched the top radiator hose (honest, barely touched it) and it came loose. I simply retightened it and it leaked badly when started. When I took it off I found that the entire plastic outlet tube was crumbled. Luckily none of it broke loose and entered the engine. I read on the IPD site that these radiators ususally last 8 years or so. Mine is 16 years old. Can it be repaired at a local shop or do I just need to purchase a new one? It is number 1346839 and is for an automatic tranny. Also, could I have tightened it so tight that it broke it or is it more likely that it was brittle due to age?
Thanks

Post by **billofdurham** » 25 Oct 2009, 17:06

If the broken bit was metal I would say, "Get it mended." With plastic I doubt if it would mend.

8 years is the time usually quoted but, like yours, I have known them go a good deal longer.

I think it's time to replace it.

Bill.

(honest, barely touched it)

Was it a big hammer or a little one?

B.

240Dad · Post by **240Dad** » 31 Oct 2009, 08:25

Bill,
For the record, I always use a big hammer first then wonder why I didn't start with the little one.

Anyway, I ordered a new radiator from a local shop that gets them at a great price. (For some reason I have replaced 3 radiators in the last year on 3 of my cars.) I took the old one with when I went to pick up the new one and they looked identical. However, the new one is about 1/2 inch taller so the upper brackets don't fit correctly. I, being a farmer by birth, worked around it by removing the rubber spacers under the radiator which dropped it about 1/2 inch and now it fits fine. Question, will removing the spacers come back to bite me later or should it be alright?

I think I have officially rebuilt the entire car since March '09. I know that I have about 3 times more in it than it would sell for around here. (Upper East Tennessee is not really Volvo country.) But, it is a pretty good car now and it is what my little girl wanted.
Thanks,
Bill

Post by **billofdurham** » 31 Oct 2009, 12:39

All of the mechanics I know only have a big hammer. Well, there is one exception and he has a bigger hammer.

The rubber spacers, Volvo calls them cushions, are there to stop the radiator rubbing on metal which could, over a very long period of time, cause a leak from the bottom of the radiator. However, I have come across this problem before, albeit with a non-Volvo make of car using an after-market radiator. The solution, passed on by a mechanic with 40+ years in the trade, was to slip two thin pieces of rubber under the radiator to replace the cushions. It has the same effect.

Bill.

240Dad · Post by **240Dad** » 31 Oct 2009, 15:14

Excellent suggestion.
Thanks, Bill