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The 1st friday of spring break, I got home and my radiator cracked in the same place. A 1995 940. *This* must be the year to replace your radiator if you have a '95... :)
Expoy did not hold, roughing and cleaning was a waste of time. JB is the way to go. a couple of Brickboarders (steve included) suggested using a combination of materials to get me through the several days it took my new rad to arrive.
This worked for me:
1) Drill a small hole in each end of the crack, it prevent further breakage.
(You can drill additional holes on each side if you wish to aid in "gripping").
2) "Groove" out the crack and make it *very* clean.
3) Apply a coat of JB weld over the whole shoulder, crack, and everything on the flat surface.
4) Apply a layer of fiberglass tape (the mesh that we use for drywall) Let it set a bit and apply another layer of JB weld, completely seal the tape in.
5) Repeat 3 & 4 as many times as you wish. I had two-three layers to cover the tape and to seal the drill holes completely.
6) Let the JB weld harden completely
7) LOOSEN your expansion tank cap. This will prevent pressure build up.
8) Don't drive very far. My repair last from Sunday until the Thursday that my new expansion tank and radiator arrived. The repair held fine, but I didn't want to push it.
BTW, The radiator replacement procedure can be done in under an hour.
Take some pictures if you can. My camera conked out and didn't advance any of the film that I shot, so I didn't get any photos. The 940 removal is more straightforward than the FAQ suggests. You do not need to remove the airdam. The Rad sits on some rubber bumper brackets and is not screwed into anything at the bottom.
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