XJ XJ6 / XJR6 ( X300 ) 1995-1997

Radiator Upper Hose Connector

Old 02-14-2019, 02:32 PM
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Default Radiator Upper Hose Connector

While replacing the AC idler pulley, I was working past the upper radiator hose, and bang! the hose popped off the radiator - the lip on the upper hose connection cracked off (see pic). Obviously, I can replace the entire radiator but is there any other solution? Is there a way to replace the plastic composite connection without replacing the whole radiator? Without half the lip, I'm not confident that the hose clamp will hold the hose under pressure.

Thanks in advance -- 1997 Vanden Plas.

Old 02-14-2019, 02:42 PM
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You could try to replicate the lip with JB weld perhaps? Insert a cardboard tube to support the JB, probably best as a rad out job for convenience?
Old 02-14-2019, 03:09 PM
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I have 2/3 of the lip that broke off, I'm thinking of gluing it back on w/ JB Weld and putting a dab of non-hardening sealant on the flat section. Worst that could happen is that it would let loose -- I use this car as my local daily driver, it would be inconvenient but not the end of the world.
Old 02-15-2019, 04:27 AM
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If I was attempting a repair on that I think I would cut off the remaining lip and try to find a suitable stainless steel or aluminium tube with a built in lip to fit snugly over the stub that is still on the radiator, and JB Weld that on. You would have a good surface area for the JB Weld to work with. Something like this one

I think trying to glue the broken bit on will fail quickly.
Old 02-18-2019, 10:39 AM
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This happened to my 1994 XJ40 about 4 yrs ago.

I purchased another radiator, but in the interim I fitted 2 hose clamps and used some baling (iron) wire tied around the "back" hose clamp. Pulling the wire forward and finding a convenient hole in the bodywork, I made several loops forward and twisted the wire to tie it off. This rear clamp, pulled forward with the wire prevented the top hose from backing up and falling off.

Not too obtrusive and to be honest, I sort of forgot about it until I read this thread.

BTW, the new rad sits in my storage and the 2 clamp "repair" still holds.

Old 02-20-2019, 10:35 AM
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Don't take chances, replace the rad. Even though it is only the hose neck right now, the rest of the tank is just as brittle and could fail without warning.
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