Be careful where you apply pressure when doing stupid little jobs underhood.

I was replacing one of the crappy URO air cleaner bushings/'feet' I installed a few months back and my elbow was pressing on the rad-to-tank overflow hose. All of a sudden, SNAP and WHOOSH. Spout broke clean off rad.

Okay so it's just about dark and around 32 deg F outside.

I ended up sitting holding the spout in place while I attempted to get JB Weld to set up at this ridiculous temp. My neighbours are now convinced I'm insane, sitting in the dark with the hood open on my car, with a hairdryer going.

Of course the repair isn't holding properly. Has anyone found something to sleeve the spout back on with? Or am I just blowing wind up my own @@@ on this one? Thanks

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Mac
2002 e320 4matic estate│1985 300d│1980 300td
Previous: 1979 & 1982 & 1983 300sd │ 1982 240d

“Let's take a drive into the middle of nowhere with a packet of Marlboro lights and talk about our lives.” ― Joseph Heller, Catch-22

There was a report of a repair using a metal outer mount tire valve stem, minus the valve core, of course. Hole drilled in nipple location, then valve stem pulled in with a wire through the upper hose port.

Take a look at Gorilla part #VS401C.

Great, thanks.

I am going to install a new rad as it's too cold to muck about now and I have no garage... but I wanted to keep this rad as a spare to repair, as I think I have another turbodiesel coming to live here in the next while....

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Mac
2002 e320 4matic estate│1985 300d│1980 300td
Previous: 1979 & 1982 & 1983 300sd │ 1982 240d

“Let's take a drive into the middle of nowhere with a packet of Marlboro lights and talk about our lives.” ― Joseph Heller, Catch-22

As far as I can tell, a Nissens radiator is just as good as a Behr and usually costs a lot less.

I'm not sure we can even get Behr here anymore (not that I'd want one anyway). I know they weren't being stocked when I ordered the rad for my old TD in 2010.

I'm always SO careful of the radiator neck when I'm working... never gave a second's thought to the overflow spout.

See my other thread about the all-metal NOS rad I've been offered....

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Mac
2002 e320 4matic estate│1985 300d│1980 300td
Previous: 1979 & 1982 & 1983 300sd │ 1982 240d

“Let's take a drive into the middle of nowhere with a packet of Marlboro lights and talk about our lives.” ― Joseph Heller, Catch-22

Someone had a post on here with pictures of a small threaded and barbed pipe nipple which they screwed into place. I'll see if I can find it.

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1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13

Can't find it but it wasn't the tire valve repair. It was a fitting that threaded nicely inside the remaining plastic.

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1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13

See post #15 here:

http://www.peachparts.com/shopforum/diesel-discussion/290075-overflow-tube-broke-radiator.html

Wow that's great. I sent a note to The Gears asking what exactly that fitting is.

I am still going to replace the rad as I am down to one car on the road right now, so I'd rather have it done with.

But I intend to repair the original rad just the same.

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Mac
2002 e320 4matic estate│1985 300d│1980 300td
Previous: 1979 & 1982 & 1983 300sd │ 1982 240d

“Let's take a drive into the middle of nowhere with a packet of Marlboro lights and talk about our lives.” ― Joseph Heller, Catch-22

I'd take that rad and throw it as far over the hill as I could. having a rad go bad on the road is really inconvenient.....don't ask how i know.

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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.

If the plastic has "aged" to the point where the overflow nipple can break, how much longer until the top hose connection likewise fails.

I agree with Tom, replace it with new, and discard that old radiator.

How many other cars last long enough for this to even be a problem.

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1982 300SD " Wotan" ..On the road as of Jan 8, 2007 with Historic Tags

I agree to a point. I only plan to fix and keep it as an "in case of emergency on a Friday evening, break glass" backup (all my problems occur half an hour after the parts shops close or on long weekends, it's bizarre).

However, as someone else pointed out, part of the problem is that the connector hose running to the overflow tank is really too short. Add some age shrinkage into that and you have a minor issue to begin with... the hose pulls backward/sideways on the spout all the time.

Plus in this case, I have to be honest and say I was rushing and I probably put a lot of load on the hose (wasn't paying proper attention). I'm a big guy and I always have to be careful where I lean my elbows as I work under the hood. This isn't the first time I've fubared something valuable while fixing something worth minor $$$.

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Mac
2002 e320 4matic estate│1985 300d│1980 300td
Previous: 1979 & 1982 & 1983 300sd │ 1982 240d

“Let's take a drive into the middle of nowhere with a packet of Marlboro lights and talk about our lives.” ― Joseph Heller, Catch-22

That makes you no different from me, or about 75% or more of all of is on this forum.

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1982 300SD " Wotan" ..On the road as of Jan 8, 2007 with Historic Tags

Thanks. I wasn't feeling well to start with (I broke my own rule about not wrenching when under the weather) and I beat myself up pretty bad on this one.

The only reason I was under there was that I had one rubber air cleaner bushing that had come loose and it was rattling a bit at idle. I was living with it, but not feeling well it got on my nerves as the day wore on, so.... And then we were here.



Cheers to all.

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Mac
2002 e320 4matic estate│1985 300d│1980 300td
Previous: 1979 & 1982 & 1983 300sd │ 1982 240d

“Let's take a drive into the middle of nowhere with a packet of Marlboro lights and talk about our lives.” ― Joseph Heller, Catch-22

I damaged the rad on an '82 300SD the same way. Snapped the overflow pipe clean off at the tank. This happened the night before i was to leave on a 9 hour drive to good ol' sunny and hot Florida. I bought the epoxy putty and a barbed brass pipe coupler. Luckily this happened to me in the summer so after the car sat over night the overflow pipe worked perfectly. I sold the car a year later (2005) and last year the guy who bought it from me told me that the rad that I repaired was still in the car and leak free. Sounds good to me!

Kevin