My son recently purchased a 940 wagon (1993 non-turbo, 176k miles)and I'm helping him get it road worthy for a move from Topeka to St Cloud. I noticed that the radiator had some seepage from the right side tank, so I thought it would be a good idea to fix it prior to his trip. I removed the radiator & took it to a local radiator shop. The proprietor told me that it was a replacement since it had brass tanks, and that is was too far gone to repair due to a large percentage of the fins being corroded away. I ordered a new radiator (Nissens), upper & lower radiator hoses, rad to reservoir hose, and a 92 deg thermostat and expect shipment later this week.

My question has to do with installing the thermo switch from the old rad & into the new. I am unclear as how it is held in position on the old rad (possibly a hex nut & a rubber bung)but I don't expect too much trouble there. But what about re-installation? I already have determined that prudence would dictate I install the switch with a new gromment - not a problem. Any tricks or techniques recommended other than boy butter & brute force?

Thanks for your time,

Joe in St Louis

When you replace the thermal switch it is so much easier if the radiator is laying on its front on the cardboard box it cam in. It takes a good force to push it in.

Spray a little PB Blaster on the transmission line connections while you are waiting for radiator. The real fear is the tube end fitting not breaking free of the tubing. Reinstall using an anti-seize.

Tom

Dear Joe,

May this find you well. The radiator may come with a rubber grommet. If so, push into the opening, and then lubricate the inner surface of the grommet with some saliva. Then, press in the temp sensor. This should not take a huge amount of pressure. If there is no grommet, get one from a Volvo dealer.

When you connect the automatic transmission cooler lines, be sure to use two wrenches. One should go on the hex fitting on the radiator, to hold it a-b-s-o-l-u-t-e-l-y still, while you turn the fitting on the steel coolant pipe. Be sure to turn the fitting backwards, to "set" the thread, before you tighten it. You'll feel a "click" when the fitting thread engages that on the radiator fitting. Then, start to tighten the fitting, using your fingers or a pair or wrenches (one on the radiator and one on the line fitting).

Hope this helps.

Yours faithfully

Spook

Hope this helps.