Dear bru,

May this find You well. The Volvo Part number for the correct Radiator is 8603907-0. If You can't get this item from a Volvo dealer, get a radiator made by Nissens A/S, a Danish firm, that supplied these radiators to Volvo.

You can get this radiator for $235.00 from FCP Groton (http://www.fcpgroton.com/product-exec/product_id/2389/nm/1992_1997_Volvo_960_Radiator/category_id/93 ). Shipping is included.

I have put a Nissens radiator in my 940, and had no problems with it.

I believe that your mechanic installed in your 960, a radiator intended for a 940. Here's the evidence: on the Volvo Vadis parts diagram for the 940 radiator, there are two parts shown - 9135545 (Thermo contact) and 1378869 (Bushing) - which two parts are not shown on the Volvo Vadis 960 Radiator parts diagram. These parts are not shown, on the 960 Radiator parts diagram, because they were never present and so are not needed as "spare parts".

These parts may be present on a 940 radiator. A '93 940 has the thermo contact. A '94 940 does not: in place of the thermo contact, there is a plastic plug, which fits into a rubber grommet (the bushing).

In short, your car needs a Nissens radiator, as set forth above. The radiator your mechanic installed is the wrong item. It might work in a 940. It should not be put in a 960. You might want to find another mechanic, who does his homework.

You're very, very lucky: based on my readings of Brickboard posts, 960s are more sensitive to over-heating than are 940s.

Hope this helps.

Yours faithfully,

Spook