Thread: All Alloy D2a TD5 radiator that is not $1K Allisport

Originally Posted by sharmy

Hi Jazzman

I fitted one of these about 18 mths ago when I broke off the overflow spiggot ( I have since refitted the old one after working out how to fix it) You will have to block off one of the small pipes at the bottom and block off and drill a smaller hole in the other.I used some alloy rod a mate turned down to size and glued them in with jb weld.It is also worth cutting out the slot that the transmission oil cooler slides in and use a different method of securing it or you will have to disconnect the oil pipes to fit it. Be careful when refitting the intercooler and make sure the locating pegs fit in the brackets on the side of the radiator or you will wear a hole in the air con condenser(I found out the hard way). I had it fitted for about 20,000 ks without any problem and it was still fine when I removed it,it seemed to run slightly cooler.
John

This is the exact reason I want to replace my radiator. I've fixed two issues with the plastic tank so far, the screw that was too long and now i've snapped the overflow pipe off. I have got myself a barb i might be able to use to fix it, but i go off road a lot and need it to be reliable.

If i understand you correctly, to fit this alloy radiator i will need to modify it? By the sounds of it, there is a outlet that is on the incorrect side and i'll need to block it off and relocate it to the other side?

Originally Posted by sharmy

Sorry onebob, posting pictures is far to technical for me
John

Also is yours a manual or auto?

HI Jazzman

Mine is an auto.The outlets are on the correct side,it is the 2 smaller outlets on the bottom drivers side that need modifying.I fixed the broken overflow outlet by using a piece of 5mm steel brake line as a internal sleeve and glued it in with jb weld.It has traveled a full circuit around oz and I have just come back from a trip to the gulf without any issues.
John

Shane, the D2A Rads are different than the original D2 rads. See this bullitan, it shows the later rad has the bottom 2 pipes blocked. Are those alloy ones open or closed at the bottom?
Cheers Mario
see attached PDF it shows the modified version used on the D2A.
TD5 RADIATOR BULLETIN.pdf

Mario
The alloy ones are both open,only one needs complete blocking off, the other is restricted.If you look carefully at the bulletin you posted you will notice that pipe D has a small hole. It is the only one of the two that has hose connected in the 2a
John

Originally Posted by sharmy

Mario
The alloy ones are both open,only one needs complete blocking off, the other is restricted.If you look carefully at the bulletin you posted you will notice that pipe D has a small hole. It is the only one of the two that has hose connected in the 2a
John

Correct

Originally Posted by sharmy

HI Jazzman

Mine is an auto.The outlets are on the correct side,it is the 2 smaller outlets on the bottom drivers side that need modifying.I fixed the broken overflow outlet by using a piece of 5mm steel brake line as a internal sleeve and glued it in with jb weld.It has traveled a full circuit around oz and I have just come back from a trip to the gulf without any issues.
John

Why did you choose to put your original radiator back in after repairing it rather than keeping the all alloy one fitted?

I had to pull it all out to replace the air con condenser and the old one looked good so I refitted it .There was nothing wrong with the alloy one it is now a spare
John