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So, at ~213k the 240 finally developed a crack in the end tank of the original plastic-and-aluminum radiator (near where the big hose from the expansion tank comes in). I needed to drive the car the next day, so I bought an all-metal radiator from the Chatham, NJ NAPA and installed it. Noticed some seepage from it onto the crossmember and the plastic bellypan - I wiped it up thinking I'd spilled some coolant when doing the job. Next day: more seepage! I took the radiator back and they replaced it in kind. The new radiator is leaking as well (and getting worse) where the tubes are brazed to the end tanks. There was also a small leak due to a loose thermostat housing, but i tightened the 'stat bolts and stopped that leak. It's definitely the radiator - the second one has lasted about two weeks.
Both radiators were from "The Radiator Store" in NJ, stamped "Made in Thailand" on the box and with a picture of a three-armed cactus on the front. They seem really lightly built - the first one had a couple of fins bend under light finger pressure. And, yes, I did use new antifreeze and flushed the system with water before replacing the radiator as the warranty instructions on the box said. I'm pretty sure that the headgasket is not leaking and overpressuring the system, either - no bubbles in the coolant, etc.
I'll ask for a refund tomorrow (which they damn well better give me or I'm charging them for labor at $75/hr in small claims court) and order a Nissens 4-core metal radiator from FCP Groton. Having to do this job three times is really obnoxious - not that it's hard to do, but I'd still prefer not to emulate Sisyphus.
-b.
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