Removal and Installation

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 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 & LIFTING .
Drain the cooling system. For additional information, refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
Remove the push pin retainers and upper air deflector.

Fig 1: Removing Push Pin Retainers & Upper Air Deflector (6.0L Diesel)
Courtesy of FORD MOTOR CO.
Remove the bolts for the power steering reservoir bracket.

Fig 2: Removing Power Steering Reservoir Bracket (6.0L Diesel)
Courtesy of FORD MOTOR CO.
Remove the bolts and power steering fluid indicator. Remove the power steering reservoir mounting bracket. Install the power steering fluid indicator and position aside.

Fig 3: Removing Power Steering Reservoir Mounting Bracket (6.0L Diesel)
Courtesy of FORD MOTOR CO.
Disconnect the coolant hoses from the air cleaner outlet tube.

Fig 4: Disconnecting Coolant Hoses From Air Cleaner Outlet Tube (6.0L Diesel)
Courtesy of FORD MOTOR CO.

NOTE: Air cleaner side shown, other side similar.

Fig 5: Removing Air Cleaner Outlet Tube (6.0L Diesel)

Courtesy of FORD MOTOR CO.

Loosen the clamps and remove the air cleaner outlet tube.
Loosen the clamps and remove the charge air cooler pipe.

Fig 6: Identifying Loosening Torque Of Charge Air Cooler Pipe Clamp Bolt (6.0L Diesel)
Courtesy of FORD MOTOR CO.

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

Fig 7: Loosening Torque For Charge Air Cooler Hose Clamp Bolts (6.0L Diesel)

Courtesy of FORD MOTOR CO.

Loosen the clamps and remove the charge air cooler hose.
Disconnect the radiator vent hose.

Fig 8: Disconnecting Radiator Vent Hose (6.0L Diesel)
Courtesy of FORD MOTOR CO.
Disconnect and remove the upper radiator hose.

Fig 9: Removing Upper Radiator Hose (6.0L Diesel)
Courtesy of FORD MOTOR CO.

NOTE: Left side shown, right side similar.

Fig 10: Removing Push Pin Retainers & Lower Air Deflector (6.0L Diesel)

Courtesy of FORD MOTOR CO.

Remove the push pin retainers and lower air deflector.
Disconnect the transmission cooler hoses.
- Plug or cap the lines as needed.
Fig 11: Disconnecting Transmission Cooler Hoses (6.0L Diesel)
Courtesy of FORD MOTOR CO.
Disconnect the lower radiator hose.

Fig 12: Disconnecting Lower Radiator Hose (6.0L Diesel)
Courtesy of FORD MOTOR CO.

NOTE: Left side shown, right side similar.

Fig 13: Removing Lower Shroud (6.0L Diesel)

Courtesy of FORD MOTOR CO.

Remove the two bolts and the lower shroud.
Disconnect the transmission cooler hoses and remove the lower shroud.

Fig 14: Disconnecting Transmission Cooler Hoses (6.0L Diesel)
Courtesy of FORD MOTOR CO.
Remove the bolts and the radiator mounting brackets.

Fig 15: Loosening Torque For Radiator Mounting Brackets Bolts (6.0L Diesel)
Courtesy of FORD MOTOR CO.

NOTE: Do not just tilt the top of the A/C condenser forward. It is necessary to position the entire A/C condenser forward. This allows the bottom of the condenser to clear the transmission cooler fittings on the radiator.

Fig 16: Loosening Torque For A/C Condenser Bolt (6.0L Diesel)

Courtesy of FORD MOTOR CO.

Remove the two bolts and position the A/C condenser forward.
Disconnect the oil level indicator and tube.

Fig 17: Disconnecting Oil Level Indicator & Tube (6.0L Diesel)
Courtesy of FORD MOTOR CO.
Remove the cooling module from the vehicle.
To install, reverse the removal procedure.