After battling coolant leaks for a while on my 90 244, I tracked the issue down to a bad connection between the upper, largest radiator hose and the radiator. However, after some investigating, it seems like the source of my bad connection is that part of the radiator has broken off inside the hose. What can I do about this? Do I have to buy a new radiator to repair that part?
Thanks.

 

Clear out the broken pieces first... Than position the hose over the outlet if you have at least 3 inches from end piece i would just reclamp it. But check the remaining outlet first for brittleness by gently squeezing the sides. If it cracks easily then its time for new/ used radiator!!!

Goldenblock

 

Replace the radiator, or if you can find someone to replace the side tank (you won't be able to) simply replace the side tanks (the aluminum tabs will break when they are bent out and then back in with a new tank)

 

If you need any radiator we have plenty Oem volvo radiators
Also Nissens 3 row all metal radiators and volvo Blackstones.

Visit L&D volvo parts atl Craigslist
and shoot me an email

Goldenblock

 

Thanks, Goldenblock and Hoonk! I will just order a new radiator with the parts order I was already going to put in at IPD.

 

If I had no source for a new one, I would find a piece of copper or aluminum tube that fit inside the opening and epoxy it in as a reinforcement, maybe even with a couple of carefully placed rivets if the plastic would still bear the load. That said, I would not depend on the repair for long term use. Fortunately these cars span a lot of years, so parts are still relatively easy to source. Relatively.