After losing samll amounts of coolant over the past few weeks, it is clear I have a fractured radiator at the top hose connection. I've ordered the radiator, hoses and thermostat. I did go with the OEM, partly because I get a good price from a dealer where I used to live and partly because the mechanic there thought that while the all metal ones are repairable, they also also more prone to clogging than the aluminium and plastic OEM.
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John Shatzer, '97 V90 @ 105K

I replaced my radiator about a year ago because the top connection was leaking even with a new top hose. At the time I reused the Volvo coolant because it was still "Crystal" clear. I set the radiator aside for later failure analysis.

This year the coolant started to show a little rust color so I replaced it with the Volvo "all cars" stuff as before. (The previous stuff had been in about 4 years.)

I also got around to looking at the cause of the leak on the old radiator. The metal support sleave inside the upper connection had rusted and swoolen enough to split the plastic neck! The tanks themselves were fine. The external fins were very thin in spots from the NE road salts.
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'96 965 with 16' wheels at 117K. Had '85 745 Turbo Diesel for 200K.

Jbowers,

Thanks for the 'Post Mortem' on the radiator failure.

DEWFPO
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1998 S90 068,300 and 1995 964 152,300

I'd like to suggest you replace all the hoses, The two for the oil cooler and heater hoses as well. Then the two for the plastic tank as well. You've got 100K on it now and it's time. I replaced the rad on the 960 about 2 years ago and then all the hoses later. The top hose was leaking slightly and maybe it wasn't quite tight enough but I didn't want to take any chances.

Use Volvo coolant too. Check the heater valve as well.

Good luck.
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Warren Bain - '99 V70GLT G-Valve > 80K mi, 89 300SE, '96 965 >120Kmi, near Manassas Va.. Check the 700/900 FAQ via the 'features' pull down menu. This post written with 100% recycled electrons.

I thought the OEM was plastic. It sure was on my 97 V90 and my older 88 740. I installed rads with copper tanks on both cars after the top necks crumbled. Never will I buy a plastic radiator. Cannot comment on aluminum.
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David Hunter

I looked lots of places and was told no one made an all-metal radiator for my 1998 V90, so I had to get another with plastic tanks. Please tell me where to buy an all-metal radiator. Thanks.

FCP Groton, although it's listed for the 97 960. I don't believe there were any model year changes for that item.
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John Shatzer, '97 V90 @ 105K

Wow. That sucks. I bought my plastic one from FCP because they were one of ones that told me I could not get an all-metal one : ( I really don't like parts people who don't know what they're talking about.

Well, don't be too quick to condemn; it may be me who is wrong. My only reasoning is that they list the OEM from 92-97 for the 960. Since the 97 960 and S/V/90 are indentical cars, save for some trim (to the best of my knowledge), I also assume that the 98 model year also fits into this coommonality. So, my inferences may be flawed. Regardless, there is some thinking that suggests that the aluminum core is less susecptible to clogging than the all metal. The inlet/outlet necks seem to be their vulnerability.
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John Shatzer, '97 V90 @ 105K

The core is aluminum on the OEM. Only the frame is plastic, as well as the inlet/outlets.
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John Shatzer, '97 V90 @ 105K

I had the same thing going on, was able to put off replacing it for a while by occasionally adding coolant (probably foolishly living dangerously!) Went ahead and bought an oem also (by nissens) which I got for $179 (free shipping) from eeuroparts. Replaced the two radiator hoses, too. it really didn't take all that long (less than two hours from start to cleanup, including a break for a thunderstorm that went by after I started).

One thing I hadn't anticipated was how much transmission fluid spilled out when I was removing the radiator. So either pay attention to it and/or be sure to put down some newspapers or other covering on the floor. I ended up using a 10 lb bag of kitty litter to clean up the mess I made.

Otherwise it was an easy operation.

Did you get new volvo coolant? I bought new stuff, not paying attention to it. It is not the usual type C coolant, but a new "universal" coolant for "all volvo engines."

Good luck with it. Nice not to have to worry about the leak anymore!

Mike
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Mike Brown Greenville, NC 1996 965 105K 1994 940 135K 1986 244 137K

Thanks much for the heads-up on the tranny fluid. I never would have thought about that. My part friend didn't want to ship thecoolant, so I'll get up to a dealer here and purchase a gallon over the counter. I amy just ask for the 'C' type.
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John Shatzer, '97 V90 @ 105K