Removal and Installation

WARNING: This page is about a different car, the 2002 Ford RV Cutaway, 2002 Ford Econoline, 2002 Ford E550 Super Duty, 2002 Ford E450 Super Duty, and 2002 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

All vehicles

NOTE: The fan, fan clutch and shroud must be removed and installed together due to insufficient clearance to remove them separately.

Drain the cooling system. For additional information, refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
Remove the air cleaner assembly.
Disconnect the radiator upper hose from the radiator. Position the radiator hose aside.
Disconnect the overflow hose from the radiator.

Fig 1: Disconnecting Overflow Hose From Radiator
Courtesy of FORD MOTOR CO.
Disconnect the coolant degas bottle hose from the shroud.

Fig 2: Disconnecting Coolant Degas Bottle Hose From Shroud
Courtesy of FORD MOTOR CO.

Vehicles with 4.2L, 4.6L, 5.4L engine

CAUTION: The clutch assembly nut has a right-hand thread and must be rotated counterclockwise to remove it.

Fig 3: Loosening Fan Clutch

Courtesy of FORD MOTOR CO.

Using the special tools, loosen the fan clutch.
Vehicles with 6.8L, 7.3L engine

CAUTION: The clutch assembly nut has a right-hand thread and must be rotated counterclockwise to remove it.

Fig 4: Loosening Fan Clutch

Courtesy of FORD MOTOR CO.

Using the special tools, loosen the fan clutch.
All vehicles
Carefully rotate the fan and fan clutch assembly counterclockwise until the assembly is free from the water pump. Place the fan and fan clutch into the shroud opening.
If equipped, disconnect the retaining clips from the fan shroud.

Fig 5: Disconnecting Retaining Clips From Fan Shroud
Courtesy of FORD MOTOR CO.
Raise and support the vehicle.
Disconnect the lower radiator hose retaining clamp from the shroud.

Fig 6: Disconnecting Lower Radiator Hose Retaining Clamp From Shroud
Courtesy of FORD MOTOR CO.
If equipped, disconnect the underbody splash shield from the shroud.

Fig 7: Disconnecting Underbody Splash Shield From Shroud
Courtesy of FORD MOTOR CO.
Lower the vehicle.

CAUTION: Use extreme care when removing or installing the fan, fan clutch and shroud. Failure to do so will cause damage to the radiator.

Fig 8: Removing Fan Shroud Mounting Bolts

Courtesy of FORD MOTOR CO.

Remove the mounting bolts, and the fan, fan clutch and shroud.
To install, reverse the removal procedure.
- Install an appropriately sized worm drive-type clamp in place of the constant tension clamp.