Section 03-03: Engine Cooling
1996 F-150, F-250, F-350, F-Super Duty, Bronco Vehicles and F-250, F-350 and F-Super Duty Vehicles with 7.3L Diesel Engines Workshop Manual
REMOVAL AND INSTALLATION

Radiator

Removal

  1. Drain the cooling system. Refer to Cooling System Draining, Filling and Bleeding in the Cleaning and Inspection portion of this section.

  1. On a Bronco vehicle, remove air cleaner intake tube.

  1. Remove the radiator overflow hose (8075) from the radiator (8005).

  1. Remove the two upper attaching screws, lift the fan shroud (8146) out of the lower retainer clips, move away from radiator and place over fan. On F-Super Duty Motorhome Chassis vehicles remove the two screws at the bottom of the fan shroud.

  1. Position the upper and lower hose clamps toward the middle of hoses. Remove the upper radiator hose (8260) and lower radiator hose (8286) from the radiator connectors.

  1. Remove the heater water bypass hose (E4OD-equipped vehicles only) located directly below the overflow nipple on the radiator outlet tank.

  1. Disconnect the two automatic transmission (if so equipped) oil cooling lines from radiator fittings.

  1. Remove the two radiator upper attaching screws or bolts.

  1. Tilt the radiator back approximately 25mm (one inch) and lift directly upward, clear of the radiator support bracket (8052) and fan blade (8600).

  1. If either upper radiator hose or lower radiator hose is to be replaced, position clamp toward the middle of hose and slip the hose off the connection with a twisting motion.

  1. Lift the fan shroud off the fan and remove from the vehicle.

Installation

  1. Inspect the radiator mounting insulators (8124). Replace if necessary.

  1. Position fan shroud on fan until radiator is installed.

  1. If either upper radiator hose or lower radiator hose has been replaced, install on engine (6007) with index arrow in line with mark on fitting on engine. Position clamps.

  1. Install the heated water bypass hose (E4OD-equipped vehicles only) to the nipple located below the overflow tank.

  1. Position radiator into engine compartment to radiator support (16138), being careful to clear fan.





  1. Install two upper attaching bolts or screws. Tighten to 11-14 Nm (8-11 lb-ft).

  1. Connect the two automatic transmission (if so equipped) oil cooling lines to radiator connectors and tighten tube nuts to 16-24 Nm (12-18 lb-ft) or clamps to 4-5 Nm (35-44 lb-in).

  1. Attach upper radiator hose and lower radiator hose to radiator. Position hose on radiator connection so that index arrow on hose is in line with mark on connection. Position clamps.

  1. Position fan shroud on the lower retainer clips and attach the top of the fan shroud to radiator with two screw and washer assemblies. On F-Super Duty Motorhome Chassis vehicles install the two lower screws. Tighten screws to 6-8 Nm (53-71 lb-in).

  1. Attach radiator overflow hose from radiator coolant recovery reservoir (8A080) to radiator.

  1. Install air cleaner intake tube (Bronco only).

  1.  WARNING: DO NOT STAND IN LINE WITH OR NEAR RADIATOR FAN BLADE WHEN ENGINE IS RUNNING.

    Refill cooling system. Refer to Cooling System Draining, Filling and Bleeding in the Cleaning and Inspection portion of this section.



    Radiator Installation, F-150, F-250, F-350 and Bronco 4.9L (300 CID) Engine





    ItemPart NumberDescription
    18005Radiator
    2N804639-S2Nut
    38075Radiator Overflow Hose
    48146Fan Shroud
    58286Lower Radiator Hose
    68146Fan Shroud
    7N606677-S2Screw
    88260Upper Radiator Hose
    9N606691Screw
    10389252-S100Clamp
    118124Radiator Mounting Insulator
    128052Radiator Support Bracket
    1317B613Reservoir Assembly
    1419E525Upper Radiator Air Deflector
    15W611631-S36Screw
    168B407Lower Radiator Air Deflector
    A—Tighten to 5-8 Nm
    (44-71 Lb-In)
    B—Tighten to 11-14 Nm
    (8-11 Lb-Ft)
    C—Tighten to 25-30 Nm
    (18-22 Lb-Ft)
    D—Line Up Paint Stripe with Boss on Connector


    Radiator Installation, F-150, F-250, F-350 and Bronco 5.0L (302 CID) and 5.8L (351 CID) Engines





    ItemPart NumberDescription
    117618Windshield Washer Reservoir
    2389252-S100Clamp
    3381440-S200AHose, Overflow
    4N804639-S2U-Nut, M6 x 1.0
    519E525Air Deflector, Performance Truck Only
    68005Radiator
    78260Upper Radiator Hose
    88286Lower Radiator Hose (5.8L)
    98286Lower Radiator Hose (5.0L)
    108146Fan Shroud
    11N807151-S2Screw and Washer, M6 x 1.0
    A—Line Up Paint Stripe Front Side of Hose
    B—Line Up Paint Stripe with Boss on Connector


    Radiator Installation, F-250 HD, F-350 and F-Super Duty Chassis Cab with 7.5L (460 CID) Engine





    ItemPart NumberDescription
    117618Windshield Washer Reservoir
    2389252-S100Clamp
    3381440-S200AHose
    4N804639-S2U-Nut
    519E525Deflector
    68005Radiator
    78260Upper Radiator Hose
    88286Lower Radiator Hose
    98146Fan Shroud
    10N807151-S2Screw and Washer
    A—Align Arrow at 12 O'Clock Position
    B—Align Arrow to Boss
    C—Tighten to 5-7 Nm
    (44-62 Lb-In)


    Radiator Installation, F-Super Duty Motorhome Chassis





    ItemPart NumberDescription
    18260Upper Radiator Hose
    28124Radiator Mounting Insulator
    3N801731Nut
    48A080Radiator Coolant Recovery Reservoir
    58286Lower Radiator Hose
    68005Radiator
    7N606691Bolt
    88146Fan Shroud
    9N620482Nut
    10N620481Nut
    118052Radiator Support Bracket
    12N606064Bolt
    1352721Bolt
    14N605786Bolt
 

Aluminum Core Downflow, F-Super Duty Commercial Chassis, 7.3L Diesel

Removal

  1. Drain the Cooling System. Refer to Cooling System Draining, Filling and Bleeding in the Cleaning and Inspection portion of this section.

  1. Remove the 3/8-inch rubber radiator degas hose from the radiator.

  1. Remove the attaching bolts and lift the fan shroud back and place it over the fan.

  1. Loosen the upper radiator hose clamp and remove the upper radiator hose from the radiator.

  1. Disconnect the two automatic transmission (if so equipped) oil cooling lines from radiator fittings.

  1. Disconnect the heated water bypass hose attached to the radiator filler neck (E4OD-equipped vehicles only).

  1. Remove the four radiator attaching bolts.

  1. Tilt the radiator back approximately 25mm (one inch) and lift directly upward, clear of the radiator support.

  1. If either upper radiator hose or lower radiator hose is to be replaced, loosen clamp at the engine end and slip the hose off the connection with a twisting motion.

  1. Lift the fan shroud off the fan and remove from the vehicle.

Installation

  1. Position fan shroud on fan until radiator is installed.

  1. If either upper radiator hose or lower radiator hose has been replaced, install on engine with index arrow in line with mark on fitting. Install constant tension clamps.

  1. Position radiator into engine compartment to radiator support, being careful to clear fan blade.

  1. Install the radiator with four bolts and tighten to specifications.

  1. Connect the two automatic transmission (if so equipped) oil cooling lines to radiator connectors and tighten tube nuts to 16-24 Nm (12-18 lb-ft) or clamps to 4-5 Nm (35-44 lb-in).

  1. Attach upper radiator hose and lower radiator hose. Install constant tension clamps.

  1. Attach the heated water bypass hose (E4OD-equipped vehicles only).

  1. Position fan shroud to radiator and attach with two bolts. Tighten bolts to specifications.

  1. Attach 3/8-inch rubber radiator degas hose from radiator coolant recovery reservoir to radiator.

  1.  WARNING: DO NOT STAND IN LINE WITH OR NEAR RADIATOR FAN BLADE WHEN ENGINE IS RUNNING.

    Refill the cooling system. Refer to Cooling System Draining, Filling and Bleeding in the Cleaning and Inspection portion of this section.



Radiator Installation, 7.3L Diesel





ItemPart NumberDescription
18592Water Hose Connection (Upper)
28260Radiator Upper Hose
3N606677-S2Screw and Washer, 1 x 1.25 Hex
48146Shroud
5N800854-S2U-Nut
68005Radiator
78C351Hose
88287Clamp
9—Transmission Cooler Lines (See Group 07)
108286Radiator Lower Hose
118592Water Hose Connection (Lower)
128501Water Pump
 

Radiator, Downflow, F-Super Duty Commercial Chassis

Removal

  1. Drain the cooling system. Refer to Cooling System Draining, Filling and Bleeding in the Cleaning and Inspection portion of this section.

  1. Remove the 3/8-inch rubber radiator degas hose from the radiator.

  1. Remove the two or four attaching bolts and lift the fan shroud back and drape it on the fan.

  1. Loosen the upper and lower hose clamps at the radiator and remove the upper radiator hose and lower radiator hose from the radiator connectors.

  1. Disconnect the two automatic transmission (if so equipped) oil cooling lines from radiator fittings.

  1. Disconnect the heated water bypass hose attached to the radiator filler neck (E4OD-equipped vehicles only).

  1. Remove the four radiator attaching bolts.

  1. Tilt the radiator back approximately 25mm (one inch) and lift directly upward, clear of the radiator support.

  1. If either upper radiator hose or lower radiator hose is to be replaced, loosen clamp at the engine end and slip the hose off the connection with a twisting motion.

  1. Lift the fan shroud off the fan and remove from the vehicle.

Installation

  1. Position fan shroud on fan until radiator is installed.

  1. If either upper radiator hose or lower radiator hose has been replaced, install on engine with index arrow in line with mark on fitting. Install constant tension clamps.

  1. Position radiator into engine compartment to radiator support, being careful to clear fan blade.

  1. Install the radiator with four bolts and tighten to specifications.

  1. Connect the two automatic transmission (if so equipped) oil cooling lines to radiator connectors and tighten tube nuts to 16-24 Nm (12-18 lb-ft), or clamps to 4-5 Nm (35-44 lb-in).

  1. Attach upper radiator hose and lower radiator hose. Install constant tension clamps.

  1. Attach the heated water bypass hose (E4OD-equipped vehicles only).

  1. Position fan shroud to radiator and attach with two bolts. Tighten bolts to specifications.

  1. Attach 3/8-inch rubber radiator degas hose from radiator coolant recovery reservoir to radiator (where applicable).

  1.  WARNING: DO NOT STAND IN LINE WITH OR NEAR RADIATOR FAN BLADE WHEN ENGINE IS RUNNING.

    Refill cooling system. Refer to Cooling System Draining, Filling and Bleeding in the Cleaning and Inspection portion of this section.