Thanks guys.

Yeah, in the back of my head I knew that the radiator would probably have to go. I was just curious if anyone found a miracle cure.

Thanks again all.

Seth

The exact same thing happened to my 940. I have read that you cannot expect much longer than 8 to 10 years from these radiators. I got closer to 15 years. If you have time & money, just replace it. There is no good fix for this plastic even if you get it repaired somehow- it will leak in 3 or 4 months. The replacement rad can be had for about $150... shop around prices vary. Get the cheap plastic tank radiator and spend a couple of extra bucks to replace hoses if you need to. under $200 for the whole job including coolant. 1 hour in the driveway maybe 2. replacement is good for 10 years and then no head gasket blown because of overheating.

It's in the FAQ, common problem that motivates many to replace their radiators before they fail. For your car, do NOT buy a metal radiator but rather replace it with a similar plastic-aluminum unit from Nissens or Volvo OEM. The aluminum engine is more subject to corrosion and adding brass/solder to your cooling system will accelerate it. Use only Volvo C or Zerex G-05 coolant, NOT green Prestone or orange Dexcool.
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See the 700/900 FAQ at the drop-down menu above right.

I had the same thing happen on my 95 960. Luckily, I was at a stop light, and there was no head damage. Consider your self lucky that the neck came off while you were at a stop.

The problem is the rads are plastic cap ends instead of metal. I looked into the glue option as well. I decided that the very high pressure, heat, and unknown reaction of ethylene glycol with a chemical adhesive was too great a risk.

I believe a company called Nissens makes the Volvo rads. These can be purchased at a considerable savings over the Volvo rad. These are, however, also plastic cap rads.

I understand that there are also metal rads available, but I have not researched these at length.

FWIW, I would bite the bullet and replace the rad rather than risk a second failure, potentially on a highway, in a remote location.