A re-core is fine. The trick is finding a small shop that does some high volume. Most of these shops take the time to do it right the first time because they do not want rad's. coming back.

The tanks are crimped on and use gaskets. The most common failure is a split or cracked plastic tank end. It is also possible to bump the tanks or bump one of the crimps. This can cause a small leak between the tank and the core. These leaks are easily fixed as long as the core is in good shape.

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AJ

1985 300D (SOLD)

diesel 911,
Copper/Brass always if there is a choice! 'Heavier,YES BUT the babies can be
"Recored".(WITH METAL TANKS!)

The problem with Aluminum core Radiators with Plastic tanks:
1.Little Aluminum "Tangs" are bent over at a 90+ DeGree angle to "Hold" the
Plastic Tanks(with their rubber o-rings for seal between the Plastic Tank and
the Aluminum core) on.
2.The "Tangs" suffer from both Heat + Mechanical (Unbend + then Rebend)
stress AND MANY times fail at or soon after "Servicing".
3.Looking at the designs,It's possible that servicing Was Not Considered
I.E. "One Time Use Only" on the "Tangs".
You would have to ask an Expert in things Metallic,someone like Kestas.

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'84 300SD sold
124.128

My new all metal radiator arrived today and it looks like a good match for the OE Behr.
There is one difference however, it has no bottom drain! The mounting posts on the bottom of the rad are similar to the Behr but they are sealed with no provision for a drain.
A bit of a hassle for future coolant changes pulling off the lower rad hose.

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1981 240D 143k 4 spd manual -SOLD

2004 VW Jetta TDI 5 speed 300k -still driven daily

Didja get it from 1-800-RADIATOR ? .

I just bought one for my 1980 300CD , it works great but like yours , has NO DRAIN PLUG !

The brackets for attaching the oil cooler were also poorly formed and needed mucho dressing with duck bill pliers erc. before I could make it work . the tanks are made of paper thin brass .

My other 300CD has a cracked filler neck so I headed off to Pick-A-Part and found an older production all metal radiator , it's visably better quality plus the oil cooler brackets are properly made . I decided to have it re-cored with a big three row core instead of the original two row style core .

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-Nate
1982 240D 408,XXX miles
Ignorance is the mother of suspicion and fear is the father

I did then what I knew how to do ~ now that I know better I do better

IMHO, if your current radiator is an all metal one, I would have it rebuilt. Unless the core is damaged (sucked a gnu through it), most radiator shops can leak test it, tear it apart, braze the leaks shut, and put it back together. FYI, I had a Volvo radiator modified to fit my needs for under $70.

IMHO, the original metal radiators are quite decent and can be kept forever.

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Your TACH may have a loose connection...I was wondering why your mechanic would be dead one minute then flopping around the next... PanzerSD

i am inspired. i will replace my windsheild... with an intercooler. swedishK

FYI,
Behr weighs 8#
CSJ (New Rad) 10# with the tank brass thickness +- .035".

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1981 240D 143k 4 spd manual -SOLD

2004 VW Jetta TDI 5 speed 300k -still driven daily

I was reinstalling the inner fender liners for the final buttoning up after the the latest last bit of rusty spot repair when I noticed a small puddle of water under the new radiator!
I crawled under and checked the lower hose and all the hoses for that matter for a leak but could find nothing; however the lip of the lower tank has some coolant on it which makes me think about a hole or crack in the rad itself.
I was too bummed to start removing all the newly installed hoses and the like to check it now.
And I finally got all the air out of the heating system.

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1981 240D 143k 4 spd manual -SOLD

2004 VW Jetta TDI 5 speed 300k -still driven daily

Just step away from the benz, take ten deep breaths and sleep on it.

Tomorrow look at it with a fresh mind and track down the source of the leak. Odds are its not your new rad.

Good luck!

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[SIGPIC] Diesel loving autocrossing grandpa Architect. 08 Dodge 3/4 ton with Cummins & six speed; I have had about 35 benzes. I have a 39 Studebaker Coupe Express pickup in which I have had installed a 617 turbo and a five speed manual.[SIGPIC]

..I also have a 427 Cobra replica with an aluminum chassis.