With Screwdriver

NOTE: The tabs on the vacuum-brazed aluminum radiator are easily broken off and require special attention to prevent tab damage.

The radiator tanks are molded, glass-filled nylon and have integral radiator and shroud brackets. The radiator tanks, which are two different sizes, are attached to the core header by tabs bent over the base of the radiator tank.

Procedures are given for the tank removal using a screwdriver or a Borroughs Remover Tool BT-8260-A or equivalent. Follow the manufacturer's instructions for radiator tab opening and closing tools.





REMOVAL
1. Insert the end of a medium tip screwdriver between the end of the radiator core header tab and tank. Press the screwdriver blade against the tank to pry the radiator core header tab away from the tank edge. Repeat the procedure for each radiator core header tab.

CAUTION: Do not open tabs more than necessary for tank removal.

2. Lift the tank from the radiator core header when all radiator core header tabs are open.





3. Remove the O-ring gasket from the radiator core header.

INSTALLATION
1. Inspect the gasket surface of the radiator core header to ensure it is clean and free of foreign material or damage.

NOTE: If any radiator core header tabs are missing from an aluminum radiator core, the radiator core should be replaced.





2. Check the O-ring gasket as shown to ensure it is not twisted. If the gasket is twisted, rotate one end of the gasket until it is not twisted.





3. Place a new O-ring gasket dipped in For Premium Cooling System Fluid E2FZ-19549-AA,-B or equivalent meeting Ford specification ESE-M97B44-A and place it in the groove of the radiator core header.





4. If the radiator inlet tank is being replaced and is equipped with a transmission fluid cooler, transfer the transmission fluid cooler from the old radiator inlet tank to the new radiator inlet tank.
5. Position the tank to the header using care not to scratch the tank sealing surfaces with the radiator core header tabs. Ensure the top and bottom of the tank are positioned properly.
6. Clamp the tank in position on the radiator core header with two No.200 Crimp Clamps or equivalent. Tighten the crimp clamps to compress the O-ring gasket.
7. If locking-type pliers are used to squeeze the radiator core header tabs against the tank, install a hex nut on pliers adjusting screw.
8. With the jaws of locking-type pliers closed and locked, turn the adjusting screw to position the jaws against the shank of a 10.9 mm (27/64-inch) drill bit. Tighten the hex nut on the adjusting screw against the handle to lock the adjustment in place.





9. Squeeze the aluminum radiator core header tabs down against the lip of the tank base with locking-type pliers while rotating the pliers toward the tank.








10. If a special crimping tool, such as the Borroughs Replacer Tool is used, follow manufacturer's instructions. It is important that the tool be adjusted to obtain the correct assembled height of the crimp. Refer to the tool manufacturer's adjusting procedure.
11. Squeeze down any remaining radiator core header tabs and remove the crimp clamps.
12. Leak test the radiator at 123 kPa (18 psi). Most minor leaks at the radiator core header to tank seal can be corrected by squeezing the radiator core header tabs down against the tank lip area of the indicated leak.