[divezic]

I removed my radiator from my 84 944 for the second time in 15 months and here's what I learned (for those of you who are interested):

1. When you have to remove your radiator (clutch, engine, belts, etc, etc) replace all the high rate failure parts at that point. Or else you'll be doing it again in 15 months. I replaced my radiator last year (clogged) and changed the thermostat but not the coolant temperature switch. Murphy's Law...it recently failed. Please don't ask why I had to remove the radiator to replace the temp switch. It's too embarassing to admit that I stripped the temp switch threads on radiator #2 last week and replaced it with radiator #3 this week. Which brings me to point #2...

2. Use the right tools for the job. Lose one day trying to find a 29mm socket for the torque wrench instead of trying to estimate 22 ft-lbs with a wrench. It felt like 22 ft-lbs but my threads said, "too much."

3. Haynes manual doesn't specify this but...On the ledge above the radiator, there are two strips of steel holding two rubber gromets. These rubber gromets are the upper radiator mounts. Unbolt these steel straps and remove the upper rad mounts before you get under the 944 to remove the radiator. Otherwise you'll have a tough time getting the radiator dislodged from the lower rad rubber mounts. It saves a lot of time, frustration, and knuckle skin.

4. Get ALL the air out of the coolant system. I personally use the Mouth-to-coolant-resivoir method and blew softly while cracking the bleed screw with a 12mm socket. My wife saw me do this and is still making cracks about how she caught me giving my 944 a little tongue. My recommendation, lock the garage door for this part and don't use tongue...coolant is toxic.

5. Share your experiences with us (especially the bone-head ones). I learn more from these BBS's than I ever will from Haynes.

Hope it helps, and I hope more that I made some sense.

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Dave
1984 944
Stuck in hell with a year to go.