Never done it, but I would certainly replace those O-rings. Regular nitrile (Buna-N) ones would work. If you can find Viton ones that large, that would be perfect. If the metal-metal seal doesn't work, anything resilient you can put between them would work. A thin copper washer should work, or thin rubber or Teflon washer.

I laugh at the prices for new and even used oil coolers on ebay. I grabbed one at PickNPull for ~$10 just in case.

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1984 & 1985 CA 300D's
1964 & 65 Mopar's - Valiant, Dart, Newport
1996 & 2002 Chrysler minivans

I had to do that because even with a drill press the hole did not get drilled straight. I suppose if you wanted to take a lot of time and do some file work you could level it to match the holes but why bother.

I made sure both the inside threads on the Oil Cooler and outer threads on the 18mm end of the fitting were degreased with Brake Cleaner before applying.

Just for info I once made an internal casting of an item with JB Weld Epoxy and pulled out the casting. What I found is that the JB Weld expands as it cures. Putting the casting back into the bore was a tight fit.

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84 300D, 82 Volvo 244Gl Diesel

?? Why not just buy a good used 240D oil cooler , clean and install it ? .

I just bought one in New Mexico of all places , they let me take it off so no damage .

Under $20 .

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-Nate
1982 240D 408,XXX miles
Ignorance is the mother of suspicion and fear is the father

I did then what I knew how to do ~ now that I know better I do better

If I could find one at a junk yard, that's exactly what I'd do.
There is someone selling one 2 hours away for $150.
I'd rather save 4 hours and fix it for under $20. No guarantee the used one won't leak.

pete

For some reason I don't have permission to view this link. What's in it?

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1984 300TD - der Landstreicher

There is all kinds of links below.

Repair Links
Fast navigation http://www.peachparts.com/shopforum/diy-links-parts-category/146034-fast-navigation-do-yourself-links.html

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84 300D, 82 Volvo 244Gl Diesel

Hi Pete ;

Agreed, never any real guarantee on used parts, why I mostly buy from Self - Service Junk Yards : because I get to look at the item in situ and decide if it'll be any good before I carefully remove it using the correct tools .

Have you tried the classifieds here ? there are Diesel heads all across America and junk/dead 240D engines abound along with rusted out cars...

Too spendy for me to mail you one from Los Angeles plus the damn thing is still dipping oil after I spent much time trying to drain it .

Don't despair, beat those bushes ~ there's a cheap one near you if you but look .

__________________
-Nate
1982 240D 408,XXX miles
Ignorance is the mother of suspicion and fear is the father

I did then what I knew how to do ~ now that I know better I do better