I am currently in a delema with my car that has a broken radiator inlet tube. (the on the top right of the radiator where the radiator hose clamps on to). After thorough "attempts" to replace this tube or repair it to where it would stay it was given up and the radiator as a whole needs to be replaced. The question that I have to ask is how hard is it to replace on my 1993 960. Some of the radiator sites said it was a complex job and should be done by a mechanic. Also what associated things would I need to replace along with the radiator besides the hoses.

This wouldn't be a big problem but I'm statined out in Guam and mechanics here are Extremely expensive. I can get a buddy of mine to help out with the work if its too technical or difficult. I'm not very mechanically inclined but I'm trying to do this without spending a bunch of extra money in the process. Can anyone help by referring me to another link or walk me through it on a response? Thanks for your help.

It's pretty easy, and straightforward. The ONLY thing you may have issues with are removing two very small nuts that hold the transmission (or is it oil?) cooler to the radiator. They are below the radiator and the only way to lift it out of the opening at the bottom is to remove these screws.

Other than that, you remove what is obvious.

Dear Brettskie,

Hope you're well. When rads start to leak on 900 series cars, they must be replaced. Plastic gets brittle with time and heat. This cannot be reversed.

You should consult this site's Frequently Asked Questions (FAQs), which heading is misleading. The FAQs are a repair guide for 700 and 900 series cars.

I don't own a 960, but have replaced rads on several 940s. This is not a hugely hard job. You'll need basic socket tools (metrics, 3/8" drive ratchet), the usual screwdrivers, a 10" adjustable wrench.

I'd recommend strongly using a radiator made by Nissens, the Danish outfit that supplied radiators to Volvo, when these cars were made. Nissens units will drop into place and the transmission fluid lines will fit properly. Other makes likely will not fit precisely.

Key points: when tightening the transmission fluid lines, you must use two wrenches. An adjustable wrench goes on the hex fitting on the radiator. That wrench must be held absolutely still: it must never be turned. The other wrench goes on the fitting, at the end of the transmission fluid line. The fitting, on the end of the transmission fluid line, is the only one that may be turned, to secure the line to the radiator. If the hex fitting on the radiator is turned, the in-radiator transmission fluid cooler is likely to be damaged, allowing coolant to get into the transmission fluid. The water in the coolant will damage - and if not removed promptly - will destroy the tranny.

Apart from this, the radiator replacement should be straightforward. If the coolant overflow hose is factory-original, I'd replace it. Hoses are cheap: replacement engines are costly.

You can get a Nissens radiator from www.fcpgroton.com. The part is #8603739. The cost is $249 + shipping. I'd guess they'll ship to Guam: it is a US territory.

Hope this helps.

Yours faithfully,

Spook

I got my radiator from IPD for around the same price or less. Easy install the only 'difficult' item was the trans cooler lines. I had to take the fittings from the old and transfer to the new. Not a big deal but don't toss the old stuff until it's all done.