Spectra Radiator Failure

I want to show what the most common plastic tank radiator failure looks like. This radiator was for a 2002 Ford Explorer 4.6l - one year old. It started slowly dripping at 8 months.

The plastic tank uses a seal that is compressed under pressure by the slotted "fingers". The fingers are "crimped" by a special machine that likely requires calibration. In a quality conscious manufacturing facility, the crimps would be inspected and the radiator pressure tested before leaving the factory. But Specta is classic Chinese garbage low-quality.

On the right we have correctly formed retaining fingers. On the left we have inadequately crimped retaining fingers.

A view of correctly crimped retaining fingers.

And a view of improperly crimped, which resulted in a massive leak.

Summary

Replacing this particular radiator is a lot of work (really stupid Ford design). Chinese radiators are hit or miss quality-wise, and it is obvious that the Chinese have zero regard for quality control. In this case, "made in China" is a warning label.

Definitely better to spend the extra $ for a Motorcraft radiator.