Another Radiator Failure - 70K miles

[Pete Lech]

The Germans are great with metal, but not so good with plastics, I guess.

1. My first radiator failed at 10 years, 92K miles. The outlet neck broke off, losing all the coolant. My wife was driving on the freeway and didn't notice the steam out the back of the car until flagged down. (No warning lights illuminated). Cost $2K to rebuild the warped head and replace the radiator.

2. The second just failed with a cracked side tank (not the expansion tank) at 155K miles and 7-1/2 years.

At least I caught it before any damage was done. Found a source for the OEM replacement @ $170. delivered.

It seems so unnecessary - if they just had made it right in the first place.

Thanks for letting me rant.

[Jack Dabsy]

Thanks for the rant !!
There are aftermarket rads... Full aluminium ones (zero plastic)

[jimmythepie]

Ranters are particularly welcome on this site.

[brettski]

Originally Posted by Pete Lech

The Germans are great with metal, but not so good with plastics, I guess.

1. My first radiator failed at 10 years, 92K miles. The outlet neck broke off, losing all the coolant. My wife was driving on the freeway and didn't notice the steam out the back of the car until flagged down. (No warning lights illuminated). Cost $2K to rebuild the warped head and replace the radiator.

2. The second just failed with a cracked side tank (not the expansion tank) at 155K miles and 7-1/2 years.

At least I caught it before any damage was done. Found a source for the OEM replacement @ $170. delivered.

It seems so unnecessary - if they just had made it right in the first place.

Thanks for letting me rant.

This is what I used to prevent the problems that you experienced, not cheap, bit no more risk of repeating your troubles.
Zionsville Autosport: BMW E39 - E38 Super Duty Cooling Kit

[Pete Lech]

Originally Posted by Pete Lech

The Germans are great with metal, but not so good with plastics, I guess....

Well, apologies to the makers of the radiator for casting aspersions on them. While waiting for the new radiator to arrive, I decided to take apart the old one, out of curiosity and so I could recycle the aluminum core. I discovered that there is a rectangular rubber seal between the plastic end tank, which is crimped to the radiator core. The tank showed no signs of any cracking. I believe that in installing the expansion tank, which was very tight and required a bit of effort with a rubber mallet, that I disturbed the seal, leading to the leak. The expansion tank also did not show any cracks either, when I finally got it out.

My current thinking is that it was really the o-rings on the radiator cap that were the cause of the leak, and my failure to apply the simplest solution let to a lot of work and expense for myself.