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I have a 77 Ford F150 Ranger XPT w/ 400 CID engine, automatic trans, with A/C. Several years back, the radiator started leaking around the top of the radiator. Local radiator shop, cleaned, rodded and re-soldered. This fixed it for a while. Next time, it started leaking again, from the top and it couldn't be repaired.
I bought a new radiator and 9 months later, same leak, same spot. Radiator shop got me another new radiator under warranty, November 03. This month, same deal again, leaking from the top seal. Again new radiator under warranty. Obviously, I'm not losing money on the deal and am an expert on removing/replacing the radiator, but would rather not have to do it again.
The radiator is NOT overfilled. Has anyone else experienced this type of problem or suggest a fix?
Sounds like wherever you got the radiator from needs to find a higher quality product to sell to his customers. That kind of repeat "business" would tend to irritate me after a couple of times with the exact same problem with "new" parts.
It sounds like you are gettig a pressure surge that stresses the tank seals. This can be caused by the thermostat sticking and then popping open. Try a new Robert/Shaw type. Also make sure you have the correct radiator cap and get it tested for pressure.
I'd recommend a recovery tank with the proper radiator cap. That let's you fill the radiator completely to purge air that corrodes things.