Removal and Installation

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 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 pushpin retainers and upper air deflector.

Fig 1: Identifying Pushpin Retainers And Upper Air Deflector
Courtesy of FORD MOTOR CO.
Remove the bolts for the power steering reservoir bracket.

Fig 2: Locating Power Steering Reservoir Bracket Retainers
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: Identifying Power Steering Reservoir-To-Mounting Bracket Bolts
Courtesy of FORD MOTOR CO.
Disconnect the coolant hoses from the air cleaner outlet tube.

Fig 4: Locating Coolant Hoses & Air Cleaner Outlet Pipe
Courtesy of FORD MOTOR CO.

NOTE: Air cleaner side shown, other side similar.

Fig 5: Identifying Air Cleaner Outlet Pipe & Clamp

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: Charge Air Cooler Pipe Clamp With Torque Specifications
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 Air Cooler Hose Clamps

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
Courtesy of FORD MOTOR CO.
Disconnect and remove the upper radiator hose.

Fig 9: Removing Upper Radiator Hose
Courtesy of FORD MOTOR CO.

NOTE: Left side shown, right side similar.

Fig 10: Removing Pushpin Retainers And Lower Air Deflector

Courtesy of FORD MOTOR CO.

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

Fig 12: Disconnecting Lower Radiator Hose
Courtesy of FORD MOTOR CO.

NOTE: Left side shown, right side similar.

Fig 13: Removing Lower Shroud Bolts

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: Removing Lower Shroud
Courtesy of FORD MOTOR CO.
Remove the bolts and the radiator mounting brackets.

Fig 15: Removing Radiator Mounting Brackets
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: Removing A/C Condenser

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 And Tube
Courtesy of FORD MOTOR CO.

NOTE: The cooling module (radiator, charge air cooler and fan shroud) is removed as an assembly. If it is necessary to separate the radiator from the cooling module, refer to DISASSEMBLY AND ASSEMBLY .

Remove the cooling module from the vehicle.
To install, reverse the removal procedure.