Radiator - 6.0L Diesel: Removal

WARNING: This page is about a different car, the 2008 Ford RV Cutaway, 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING article.
Drain the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding .
Remove the 6 push pin retainers and upper air deflector.

Fig 1: Locating Push Pin Retainers

Courtesy of FORD MOTOR CO.

Remove the 4 bolts for the power steering reservoir bracket.

Fig 2: Locating Power Steering Reservoir Bracket Retainers

Courtesy of FORD MOTOR CO.

Remove the 3 bolts and power steering fluid indicator. Remove the power steering reservoir mounting bracket. Install the power steering fluid indicator and position aside.

Fig 3: Identifying Power Steering Reservoir-To-Mounting Bracket Bolts

Courtesy of FORD MOTOR CO.

Disconnect the coolant hoses from the Air Cleaner (ACL) outlet tube.

Fig 4: Locating Coolant Hoses & Air Cleaner Outlet Pipe

Courtesy of FORD MOTOR CO.

NOTE: ACL side shown, other side similar.

Loosen the 2 clamps and remove the ACL outlet pipe.

Fig 5: Identifying Air Cleaner Outlet Pipe & Clamp

Courtesy of FORD MOTOR CO.

Disconnect the Mass Air Flow (MAF) sensor electrical connector. Disconnect the 3 clips and remove the ACL cover.

Fig 6: Locating Mass Air Flow (MAF) Sensor Electrical Connector & Clips

Courtesy of FORD MOTOR CO.

Loosen the clamps and remove the Charge Air Cooler (CAC) tube.

Fig 7: Locating Clamps & Charge Air Cooler (CAC) Tube

Courtesy of FORD MOTOR CO.

NOTE: If there is any oil residue, clean both connecting ports and the inside surface of the CAC hose to prevent the hose from blowing off.

Loosen the clamps and remove the CAC hose.

Fig 8: Identifying Charge Air Cooler (CAC) Pipe Clamps

Courtesy of FORD MOTOR CO.

Disconnect the radiator vent hose.
Disconnect and remove the upper radiator hose.

Fig 9: Upper Radiator Hose

Courtesy of FORD MOTOR CO.

Remove the 4 bolts and lower air deflector.

Fig 10: Locating Bolts & Lower Air Deflector

Courtesy of FORD MOTOR CO.

Disconnect the transmission cooler hoses.
- Plug or cap the hoses as needed.

Fig 11: Locating Transmission Cooler Hoses

Courtesy of FORD MOTOR CO.

Disconnect the lower radiator hose.
Remove the 2 lower shroud bolts.
Disconnect the transmission cooler hoses from the lower shroud and remove the lower shroud.

Fig 12: Locating Transmission Cooler Hoses

Courtesy of FORD MOTOR CO.

Remove the 2 push pin retainers and the closeout.

Fig 13: Locating Push Pin Retainers

Courtesy of FORD MOTOR CO.

NOTE: LH side shown, RH side similar.

Remove the 4 bolts and the radiator mounting brackets.

Fig 14: Locating Radiator Mounting Brackets Bolts

Courtesy of FORD MOTOR CO.

NOTE: Cooling module removed from vehicle for clarity.

Remove the 2 bolts and fan shroud.

Fig 15: Fan Shroud Bolts

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NOTE: LH side shown, RH side similar.

Remove the 2 A/C condenser bolts.

Fig 16: A/C Condenser Bolts

Courtesy of FORD MOTOR CO.

NOTE: Make sure the transmission cooler fittings on the radiator are not contacting the A/C condenser or damage to the A/C condenser may occur.

With the help of an assistant, raise the radiator and CAC as an assembly enough to separate the A/C condenser from the CAC. Remove the radiator and CAC as an assembly from the vehicle.