1996 Ford Aerostar putting in new radiator, taking out old

  • 6 CYL
  • FWD
  • 18,452 MILES
I need to know what I need to do to take out old radiator and put in new
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have the same problem?
Thursday, February 11th, 2010 AT 5:57 PM

1 Reply

With the engine cold, drain the cooling system by removing the radiator cap, attaching a 3 / 8 in. (9.5mm) inside diameter hose to the draincock nipple, then opening the draincock at the lower rear corner of the radiator tank. Drain the coolant out of the radiator, through the hose, and into a suitably sized container.
Remove the rubber overflow tube from the radiator and store it out of the way.
Remove the cooling fan and clutch assembly from the water pump pulley.
Remove the radiator fan shroud upper attaching screws, then lift the shroud out of the lower retaining clips. Lift it and the cooling fan/clutch out of the engine compartment.
Loosen the upper and lower hose clamps at the radiator and remove the hoses from the radiator connections.
If equipped with an automatic transmission, disconnect the transmission cooling lines from the radiator fittings. Disconnect the transmission cooler tube support bracket from the bottom flange of the radiator by removing the screw.
Remove the two radiator upper attaching screws.
Tilt the radiator back (rearward) about 1 in. (25mm) and lift it directly upward, clear of the radiator support and the cooling fan.
If either hose is being replaced, loosen the clamp at the engine end and slip the hose off the connection with a twisting motion.
Lift the fan shroud off of the fan, then remove it from the vehicle.
Remove the radiator lower support rubber insulators.

To install:

Install the coolant hose(s) to the engine connections, making sure any bends are oriented exactly as the old hose for alignment purposes.
If the radiator is being replaced, transfer the lower support rubber insulators to the new part. The radiator cooling fins should be cleaned of any dirt or debris and any bent fins should be CAREFULLY straightened.
Install the radiator into the engine compartment, making sure the lower rubber insulators are properly positioned in the radiator support. Be careful to clear the fan with the radiator to avoid damage to the cooling fins.
Connect the upper attaching bolts to the radiator support and tighten them to 12-20 ft. Lbs. (17-27 Nm).
If equipped with an automatic transmission, loosely connect the two transmission cooling lines to the radiator fittings, then connect the transmission cooler tube support bracket to the bottom flange of the radiator with the attaching screw. Attach the cooler tubes to the plastic clip on the tube support bracket, then tighten the fittings at the radiator.
Attach the upper hose to the radiator, positioning the stripe on the hose at the 12 o'clock position. Tighten the hose clamp to 20-30 inch lbs. (2-4 Nm).
Position the lower hose on the radiator with the hose stripe at the 6 o'clock position, then tighten the hose clamp to 20-30 inch lbs. (2-4 Nm).
Position the shroud in the lower retainer clips and attach the top of the shroud to the radiator with two screw and washer assemblies. Tighten the screws to 4-6 ft. Lbs. (5-8 Nm).
Attach the rubber overflow tube to the radiator and coolant recovery reservoir. Refill the cooling system to specifications with the recommended coolant mixture as outlined in and add two cooling system protector pellets (D9AZ-19558-A or equivalent). If the original coolant was saved and is not contaminated, it may be reused. Allow several minutes for trapped air to escape and for the coolant mixture to flow through the radiator.
Install the radiator cap fully, then back it off to the first stop (pressure relief position). Slide the heater temperature and mode selector levers to the full heat position.
Start the engine and allow it to operate at fast idle (about 2,000 rpm) for three to four minutes, then shut the engine OFF.
Wrap a thick cloth around the radiator cap and remove it cautiously. Add coolant to bring the level up to the filler neck seat.
Install the radiator cap fully (down and locked). Remove the cap from the top of the coolant recovery reservoir and top off the reservoir to the FULL HOT mark with coolant.

Be careful not to confuse the coolant recovery reservoir with the windshield washer fluid reservoir. The two are right next to one another.
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Thursday, February 11th, 2010 AT 7:51 PM

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