Thermostat Housing Nipple

syrotchen · Post by **syrotchen** » 02 Nov 2009, 16:15

Over the weekend I took on the enormous task of replacing my cracked expansion tank (ok should be a pretty simple job.) After installing the tank, I began to reconnect the small hose off the thermostat housing and snapped the plastic nipple off at a perfect 45 degree angle. So I run inside, eager to get the part number for my seemingly $1.50 mistake quickly find the parts diagram the ID number and uh oh, no Part number. Instead, I get a note to the housing. Now, the feeling starts to set in, this isn't going to be a $1.50 mistake, its going to be $150 mistake. So I pick up the housing from Volvo, and the parts guy feels my pain and says its a bad design and there is no replacement for just the nipple. The end of the connector isn't something I recognize as a standard fitting and it mates to a quick type connector. I do notice however, the end in the thermostat housing is threaded. So now I'm starting to think about the possibility of removing a few zeros from that repair cost. Perhaps I can replace that plastic piece of garbage with a brass elbow but I cannot locate an elbow with the the "quick connect" type fitting on the other end. I'm tempted to try and replace it with barb fitting but there is one nagging voice in my head that keeps saying you have the opportunity to take that $1.50 mistake to a $1,500 mistake when the engine overheats because of restricted water flow. So a couple of questions.
1. Has anyone ever located a source for the nipple/elbow or replaced it with another fitting.
2. Anyone have any opinions on doing so?
3. Not wanting the opportunity to buy another $150 plastic nipple, I'm considering doing the timing belt at the same time. My S80 has 95,000 miles on it but looking at the belt it looks like its in very good condition. Anyway to find out if perhaps the previous owner changed the belt? We bought it with 55K miles on it, so I assumed it had never been changed.

537playing · Post by **537playing** » 02 Nov 2009, 19:12

how about looking for one in a junk yard?

syrotchen · Post by **syrotchen** » 02 Nov 2009, 23:19

Doubt it would be removable. Looking at the new part, I tried to unscrew the existing nipple so we could get a size, it would appear that some type of thread lock/glue was used. Replacing the entire housing would likely be the only option on a used part. While it is likely to save $50, given the way mine snapped off with little effort, I'm afraid a used one would be a lot more brittle and likely to snap on installation as well. Really its the fact that this is a plastic part and it should be metal which is why I asked if anyone had tried replacing it with brass type fitting.

bright · Post by **bright** » 03 Nov 2009, 01:25

First, I salute your can do attitude. I have made many work arounds for problems. Friends who are engineers can't seem to get their heads around improvisational improvements.

That said, a quick question: Is the actual thermostat housing metal or plastic? If it is metal you can meander up to a local machine shop and have them throw in a new fitting. Trust me, they'll have it.

They'll simply drill a slightly bigger hole and run a new fitting into it, much like you envision. They'll get it rock steady though. Be sure to get a price upfront and tell them you don't have a lot of cash. People see a Volvo and think of Birkenstocks, NPR and money (of which I have two but not three.)

Throw a picture in the response and I'll give you a guess.

Lee

EDay · Post by **EDay** » 03 Nov 2009, 03:37

woooo~ no other way on that, is either a new 1 or a cheaper 1 in a junk yard.

syrotchen · Post by **syrotchen** » 03 Nov 2009, 23:21

Well, given the response of the parts guy when I purchased the original housing and knowing that I'll be doing a timing belt in the near future, I figure I'm playing with the houses money until I hit $100 as he indicated these fittings break a lot. I've tried several auto part sources in town with no luck so I'm looking into a machine shop that sells performance type parts thanks Bright for the reminder.
FYI, the threads appear to be 5/16" as my 5/16" tap seem to chase threads without much effort and the side that fits the on the quick connect is 5/16" (there is a 5/16" stamped on the new connector from Volvo.

Oh, as long as there are a machine shops there is always another option. It just a question of whether or not its cost effective.

bright · Post by **bright** » 04 Nov 2009, 02:19

Not a problem. It's funny how the language of business and economics has pervaded our society. People view something as being cost-effective, etc. I trained as an economist and it still amazes me to hear people speak as such.

The ONLY time I would look at something is called "in for a penny in for a dollar" effect, or better known professionally as "Sunk Cost" http://en.wikipedia.org/wiki/Sunk_cost

It's a car, and if you love it that's a small price to pay. If she is in good shape then it is a lot cheaper than new car payments. Cars, on average, need about $750 a year maintenance to keep them on the road after they pass the age of 7 years. So I wouldn't sweat it. After all, you are providing the labour which is the dearest part.

And make a phone call or two to a machine shop. What they'll do isn't rocket science and it will be sure to stay in place. You won't have to second guess it. Take the difference and buy you and your significant other a nice meal. Damned be cost effective!

As far as utility and marginal returns, my car is a 95 960 and it sucks gas. It is traumatic to fill it up. But it would take about a decade for a newer car with better mpg to equal the cost of continued ownership and fuel consumption of the Volvo.

I plan to recover the driver seat and she'll look 90% of new.

Enjoy the car...

Lee

bright · Post by **bright** » 04 Nov 2009, 22:48

Oh, one more thing.

The part that replaces the nipple need not be performance. If it was performance to begin with Volvo would have engineered something more robust.

Something standard would fit nicely. Don't mess with a speed shop or an aeronautical machinist.

Just Joe Blow will do fine. I've have had many parts repaired inexpensively by my local grease monkeys.

Let us know how it turns out.
Lee

syrotchen · Post by **syrotchen** » 09 Nov 2009, 10:40

I ended up finding a local machine shop I found on the internet http://www.automotivemachine.com. After a few emails back and forth deciding on material, Tom Nichols fabricated a piece of stainless that worked perfect and was worthy of display. Great guy to deal with and as honest as they come. After installing the thermostat housing (what a pain) and fitting everything back together, I had a small leak where the quick connect fitting hit the hose. I had checked the dimensions on the new fitting against the old and they were an exact match, so I looked at the quick connect fitting on the hose and discovered that one of the clips on the connector was damaged, it was Saturday night and there was no way I was getting that connector before Monday, so I removed it from the hose and simply connected the hose to the fitting and used a small hose clamp. While it was a pain getting a small wrench in the recessed portion of the timing cover, it worked like a champ. If I had to do it again, I'd have Tom fab the piece with a single barb on the end and skip quick connect fitting. However, I pulled on the hose, it isn't coming off.
After reinstalling the timing cover, there is no question in my mind that this is way to go. Its a real pain trying to bend the cover over the nipple and it is easy to apply a little pressure to the nipple when doing so. If my wife's xc70 has the same setup, I'll be buying another nipple from Tom as I know I'd snap in off trying to get the cover on or off. I took a few pictures along the way and I'll post a quick write up in the repair section. While it should be a simple job I learned a few trick along the way.

bright · Post by **bright** » 09 Nov 2009, 14:50

I was hoping to hear how you solved the problem. I'm sorry that he didn't do it right the first time. It personally irritates me. I feel like a I gave you bad advice.

As soon as possible take it back to him and make him do it right. He shouldn't give you a hard time. Cut the house so you don't have to screw the worm clamp loose. Bring the hose attached and explained what went wrong. It's never a good feeling to have something ticking away in the back of your head.

I know that it will be a huge PITA to do so, but you'll gain that extra piece of mind. And you'll become that much more educated in the black arts of timing covers, etc.

Another benefit is that you'll begin to see things that once were written off as bad are easily reusable. This guy does some incredible things with items that were once dead. Check out his $50 paint job. It's a bit pricier now but it's still cool.

http://www.rickwrench.com/index79.htm

Just remember you are exchanging your time and experience for the money it would take to buy a new part.

Sorry to hear that it wasn't a perfect solution.
bright