Hey Woofpack ... I just repaired (not replaced) my 96 850 GLT radiator Now, I did this "field expedient" repair b/c this is a 200k commuter car with lots of other issues I don't feel like paying much, if anything to repair - when it really dies, it dies and I'll donate to the American Cancer Society. I have no special tools, just a regular home owner ratchet/socket set, a floor jack, and jack stands (the radiator must be dropped from under the car).

If you want to keep yours for a long time, as I guess you do if you've had it only three months, replace the radiator. The radiator will run ~$215. Budget in some more $$ for cats n dogs like new radiator hoses, pressure hose clamps for the A/T coolant hoses on the right side etc and so on ... ... hope this helps

Sypmtom: losing coolant

First troubleshooting step: added aluminum STOP LEAK from Advanced Auto...cont'd losing coolant

Next - Pull (or rather drop) radiator
-Identify Leaks: silver colored (from the aluminum in STOP LEAK) streaks showed where leakage was taking place ->> on the left as you look at the car from the front from under the upper radiator hose to the bottom of the radiator ... all along the seam between the black plastic tank and the radiator core.
-Repair Leaks: Bought JB Weld liquid steel (http://jbweld.net/products/jbweld.php - J-B WELD
Part No. 8265-S) and applied to entire length of seam repairing the multiple leaks. Let epoxy cure according to instructions.
-Re-fill radiator , run engine a bit, check for missed leaks, JB Weld again (I was able to repair the one leak - like yours under the upper radiator hose - without pulling the radiator again).
-Drain radiator again, Fill halfway with coolant, add another can of STOP LEAK, finish re-filling with coolant.
-To save money, I inspected but didn't replace hoses.
-I had to break the pressure hose clamps on the A/T cooler hoses on the right and so went to a Volvo parts department to purchase two when we re-installed the radiator.
-Pulling the radiator isn't rocket science, but it's hard to do alone - another set of hands is VERY helpful. Let me know if you want any info on that job.
-All told it took several days. Since I'd never pulled the radiator before that job took ~2hours pulling + 2h re-installing. Then the JB Weld should cure for 24 hours.

Also, if you can identify (add STOP LEAK and look for silver streaks) and access the leak without pulling the radiator, give it a try. The car will still need to sit still while the epoxy cures ... but you won't have to do so much work.



Good Luck!
Bob