With Screwdriver

(Part 1 Of 2):

(Part 2 Of 2):

The radiator tanks are moulded nylon. The tanks, which are two different sizes, are attached to the core header by tabs bent over the base of the tanks.

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

The following radiator tank procedures were developed using the radiator inlet tank. The procedure for the radiator outlet tank is similar.

REMOVAL
1. Remove the radiator.





2. Remove the four fan shroud bolts and remove the engine cooling fan motor, A/C condenser cooling fan, fan blade, and fan shroud as an assembly from the radiator.





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

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

4. Lift the tank from the core header when all of the tabs are open.
5. Remove O-ring gasket from the header.

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

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





2. Check the O-ring gasket as shown to be sure 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 Ford Premium Cooling System Fluid E2FZ-19549-AA or -B or equivalent meeting Ford specification ESE-M97B44-A in the groove of the 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 radiator inlet tank to the header using care not to scratch the radiator inlet tank sealing surfaces with the header tabs. Be sure both the top and bottom of the radiator inlet tank are positioned properly with the other radiator inlet tank.
6. Clamp the radiator inlet tank in position on the header with two crimp clamps. Tighten the crimp clamps to compress the O-ring gasket.
7. If locking-type pliers are used to squeeze the header tabs against the tank, install a hex nut on the pliers adjusting screw.





8. With the jaws of the locking-type pliers closed and locked, turn the adjusting screw to position the jaws against the shank of a 12 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 header tabs down against the lip of the radiator inlet tank base with the locking-type pliers while rotating the pliers toward the radiator inlet tank.








10. If a special crimping tool such as the Borroughs Tool is used, follow the manufacturer's instructions. It is important that the tool be adjusted to obtain the correct assembled height on the crimp.
11. Remove the crimp clamps and squeeze down the remaining tabs.
12. Leak test the radiator at 145 kPa (21 psi). Most of the minor leaks at header to tank seal can be corrected by squeezing the header tabs down against the tank lip area of the indicated leak.