Hi guys, I've been changing the trans fluid in my 940 2.3 non turbo, and when trying to reconnect the return line, it looks like it may have been stripped, along with the rad connector. How bad is this, what do I need to replace and how much is it going to be?

Dear Macafee,

Hope you're well and stay so. To what do you refer by "it" may have been stripped"?

If you mean the hex-sided steel fitting at the end of the steel pipe from the transmission to the in-radiator transmission fluid (ATF) cooler, plumber's teflon tape may give you a tight seal. Wrap a turn or two of the teflon tape around the brass male fitting that protrudes from the radiator side-tank. Hand-turn the steel hex fitting onto the tape-wrapped brass fitting. Tighten gently with a wrench.

Then, wrap the steel connector with clean white paper towel. Turn-on the engine and let it run for a couple of minutes. If the towel doesn't turn pink, you have a tight connection. Leave the paper towel there and check over the next few days. If the towel turns pink, back-off the steel hex fitting and re-wrap the brass fitting with a further layer of teflon tape. Re-test.

The brass fitting is brazed to the in-radiator copper ATF cooler. It is unlikely that you separated the brass fitting from the copper ATF cooler. I dismantled a worn-out radiator to get a look at the ATF cooler. It is made of very heavy copper (double-walled). The brass fitting is very robust.

Volvo no longer supplies the ATF pipes from the transmission to the in-radiator ATF cooler. If the steel hex fitting is totally stripped, you may need to use a heavy-duty rubber hose to connect the steel pipe to the brass fitting on the radiator's side tank. Hose made for power steering fluid - the same as ATF - will stand-up to long use. This hose can be secured with ordinary hose clamps.

You may need to use a short length of rubber hose to sleeve the steel ATF pipe, to build-up its diameter so that it matches that of the brass fitting. A second, longer length of ATF-compatible hose - with an interior diameter matching that of the now rubber-hose-sleeved steel pipe and the brass fitting - will make a lasting connection, once secured with stainless hose clamps.

Hope this helps.

Yours faithfully,

Spook

Hi Mcafee,

Where did the line break off exactly? Did you break the radiator?

I had a transmission line fitting snap once near the radiator
in my 740 and there was plenty of room to splice new steel tubing
in for just the cost of a short hunk of steel tubing some and some
junction fittings. I reused the original fitting to the radiator and
had plenty of room to work the flare tool.
There was no need to buy an expensive tranny coolant line from Volvo,
and I avoided the adventure under the car.

Next time you need to break radiator fittings give them a long soak in
Mystery Oil, overnight or longer for good luck.

Bill