Dismiss Notice



Register Today It's free! This box will disappear once registered!

Hello new member here. Help needed removing radiator from '02 Mountaineer.

Discussion in 'Stock 2002 - 2005 Explorers' started by Nasty Wendy, June 24, 2008.

  • Searches ExplorerForum.com
    1. Nasty Wendy

      Nasty Wendy New Member

      Joined:
      June 24, 2008
      Messages:
      3
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Louisiana
      Year, Model & Trim Level:
      2002 Mountaineer
      Hello everybody. I found this forum through a Google search and I'm bookmarking it in my favorites. I've read enough to know that there are some folks here that know these SUVs very well. My problem is that my radiator is leaking and I want to replace it. I cannot for the life of me get the dang thing out. Is there a set of instruction online somewhere that can give a step by step on 'How to remove the radiator'? The main problem is the lower bolt on the passenger side. I can't get to it.:frustrate I did a search and it didn't bring up much info on how to remove them. TIA.:salute:
       
    2. Support EF

      Join the Elite Explorers for $20 for 2 years!

      Explorer Forum has probably saved you that much already, and will continue to save you money as you learn how to diagnose fix problems yourself, and learn which modifications work without having to experiment on your own. Elite Explorer members see practically no ads, can add their own profile photo, upload photo attachments directly to your posts and Media Gallery, create more private Conversations, and more. Join Today. Your support is greatly appreciated.


      to hide adverts.
    3. Nasty Wendy

      Nasty Wendy New Member

      Joined:
      June 24, 2008
      Messages:
      3
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Louisiana
      Year, Model & Trim Level:
      2002 Mountaineer
      Wow 46 views and no help. I guess I asked a stumper question.
       
    4. pa944red

      pa944red Member

      Joined:
      November 17, 2004
      Messages:
      78
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Mt Holly Springs, PA
      Year, Model & Trim Level:
      02 XLT, 05 XLS
      Below are the shop manual directions. Send me your e-mail address and I can e-mail the pics that go with it.

      Tom

      SECTION 303-03: Engine Cooling 2002 Explorer/Mountaineer Workshop Manual

      REMOVAL AND INSTALLATION

      --------------------------------------------------------------------------------

      Radiator

      Special Tool(s) Disconnect Tool, Transmission Cooler Line
      307-441

      Removal

      Remove the upper air deflector.

      NOTE: 4.6L engine shown, 4.0L engine similar.

      Detach the A/C tube from the retainers.

      Remove the inner air deflector.

      Remove and discard the screws. Remove the bolt from the left side of the fan shroud.

      Remove and discard the screws. Remove the bolt from the right side of the fan shroud.

      Remove the upper radiator fan shroud.

      Drain the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section.
      Raise and support the vehicle. For additional information, refer to Section 100-02 .
      NOTE: If equipped, remove the safety retainer from the connector.

      Disconnect the cooler line.
      If equipped, use the special tool to disconnect the quick coupler.
      If equipped, loosen and remove the screw clamp from the hose.

      Disconnect the hose from the radiator, detach the hose from the retainer(s) and position it aside.

      Remove the left lower radiator hose from the radiator and position it aside.

      Remove the bolts and the lower fan shroud.

      Disconnect the lower air dam pushpins.

      Lower the vehicle.
      Disconnect the degas bottle hose and upper radiator hose.

      Remove the two bolts and the right radiator support bracket.

      Remove the two bolts and the left radiator support bracket.

      Remove the right A/C condenser support bracket.

      Remove the left A/C condenser support bracket.

      NOTE: It will be necessary to lift the radiator assembly up off the mounts and set it on the frame in order to separate the A/C condenser from the radiator.

      NOTE: RH side shown, LH side similar.

      Remove the radiator up off the mounts and set it on the frame.

      Remove the left inner air deflector from the A/C condenser.

      Remove the right inner air deflector from the A/C condenser.

      CAUTION: Do not allow the A/C condenser to hang freely or damage to the A/C lines could occur.

      NOTE: LH side shown, RH side similar.

      Using mechanics wire, support both sides of the A/C condenser.

      NOTE: It is not necessary to evacuate the A/C system. The A/C condenser can remain in the vehicle.

      NOTE: It will be necessary to lift the A/C condenser up off the lower support. Move the A/C condenser toward the front of the vehicle.

      Remove the radiator and trans cooler as an assembly and place it on a bench.

      Remove the bolts and the trans cooler.

      Remove the splash shield pin-type retainers.

      Disconnect the hose.

      NOTE: RH side shown, LH side similar.

      Remove the four bolts and the bracket.

      Installation

      NOTE: RH side shown, LH side similar.

      Position the bracket and install the bolts.

      Connect the hose.
      Install an appropriately sized worm drive-type clamp in place of the constant tension clamp.

      Install the splash shield pin-type retainers.

      Install the trans cooler and bolts.

      Set the radiator assembly on the frame.

      NOTE: LH side shown, RH side similar.

      Remove the mechanics wire from the A/C condenser and position the condenser onto the lower mounts.

      Install the right inner A/C air deflector shield.

      Install the left inner A/C air deflector shield.

      Align the lower mount and install the right A/C condenser mounting bracket.

      Align the lower mount and install the left A/C condenser mounting bracket.

      NOTE: RH side shown, LH side similar.

      Set the radiator assembly onto the support mounts.

      Install the right radiator support bracket and the two bolts.

      Install the left radiator support bracket and the two bolts.

      Raise and support the vehicle. For additional information, refer to Section 100-02 .
      Install the lower front air dam pushpins.

      Install the lower fan shroud and bolts.

      Connect the left lower radiator hose.
      Install an appropriately sized worm drive-type clamp in place of the constant tension clamp.

      Connect the hose to the radiator, and attach it to the retainer(s).
      Install an appropriately sized worm drive-type clamp in place of the constant tension clamp.

      Connect the trans cooler lines.
      If equipped, install the safety retainer on the connector.
      If equipped, install the screw clamp on the hose.

      Lower the vehicle.
      Install the upper fan shroud.

      Install the bolt on the left side of the fan shroud.

      Install the bolt on the right side of the fan shroud.

      Connect the upper radiator hose and the degas bottle hose.
      Install an appropriately sized worm drive-type clamp in place of the constant tension clamp.

      Install the inner air deflector.

      NOTE: 4.6L engine shown, 4.0L engine similar.

      Attach the A/C tube to the retainers.

      Install the upper air deflector.

      Fill and bleed the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section.
      Fill and check the transmission fluid. For additional information, refer to Section 307-01 .
       
    5. Nasty Wendy

      Nasty Wendy New Member

      Joined:
      June 24, 2008
      Messages:
      3
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Louisiana
      Year, Model & Trim Level:
      2002 Mountaineer
    6. pa944red

      pa944red Member

      Joined:
      November 17, 2004
      Messages:
      78
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Mt Holly Springs, PA
      Year, Model & Trim Level:
      02 XLT, 05 XLS
      E-mail sent.

      Tom
       
    7. E.B. Cornburner

      E.B. Cornburner Well-Known Member

      Joined:
      April 20, 2007
      Messages:
      1,137
      Likes Received:
      1
      Trophy Points:
      0
      City, State:
      Oshkosh, WI
      Year, Model & Trim Level:
      2004 Eddie Bauer
      If you haven't located a new radiator yet, or want to price shop a little, call 1-800-RADIATOR. They've got stores nationwide, and calling the 800 number will put you in touch with the closest one to you. I use them almost exclusively, and so far, I haven't found a better price or warranty anywhere. They offer lifetime warranties on all their radiators except special racing or commercial applications.
       
    8. Antho

      Antho New Member

      Joined:
      January 7, 2016
      Messages:
      25
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Brisbane, Australia
      Year, Model & Trim Level:
      2003 Explorer Limited V8
      Thread dig

      Is there any way of removing the radiator without pulling out the trans cooler

      I've watched a few videos on youtube of people doing it but they don't really show you how to get to the lower bolts
       
    9. Number4

      Number4 "I'm counting to 3, then I'm getting your dad." Elite Explorer

      Joined:
      March 16, 2013
      Messages:
      3,721
      Likes Received:
      89
      Trophy Points:
      58
      City, State:
      Woodstock, GA
      Year, Model & Trim Level:
      04 Ford Explorer 4.6l
      Yes, but it involves removing the bumper, headlights and the header panel that the headlights mount to.

      This will give you access to four holes (each just big enough for a socket, 1/4" drive? been a while) which will give you access to the mounting screws.

      I did it this way because my bumper was already off (due to a deer) but I'd go this route again. As with anything, it's not a straight shot. Mainly, putting it back together, aligning everything was a challenge.
       
    10. Antho

      Antho New Member

      Joined:
      January 7, 2016
      Messages:
      25
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Brisbane, Australia
      Year, Model & Trim Level:
      2003 Explorer Limited V8
      Managed to do it today with the front bumper and lights still in place

      Heres how I did it:
      Remove clutch fan and both shrouds (I already has these off)
      Remove top trim panel
      Remove brackets holding AC condenser to rest of cooling assembly
      Remove brackets holding cooling assembly to the body
      Remove side pastic trims in cooling assembly
      Remove top 2 radiator bolts
      Remove 2 trans cooler bolts
      Remove lower LH radiator bolt via lower cut out in bumper using 2 extension bars and a swivel 3/8 size
      Hang trans cooler up as high as possible with rope
      Lift AC condenser up and push back under wiring loom
      Lift remainer of cooling assembly of its mounts and tilt forward
      Now there is just enough access to remove the final lower bolt holding the radiator in to the bracket
      I undid it with a ratchet spanner and put it back together with a ratchet and short extension 1/4 inch size

      It was a bit of a mission but after having swapped the gearbox and transfer case it didn't seem so hard

      They don't make anything on these trucks easy do they...
       
    11. SteveTheBeave

      SteveTheBeave New Member

      Joined:
      December 12, 2008
      Messages:
      9
      Likes Received:
      0
      Trophy Points:
      1
      City, State:
      Sugar Hill, GA
      Year, Model & Trim Level:
      '02 XLT
      Is the AC condenser connected to the radiator/trans cooler assembly?

      I am trying to replace the radiator in my '02 Explorer and don't want to mess with the AC system.
       
    12. Fdz

      Fdz New Member

      Joined:
      January 11, 2018
      Messages:
      1
      Likes Received:
      0
      Trophy Points:
      1
      City, State:
      Fort worth
      Year, Model & Trim Level:
      2002 ford explore 4.6
      Hello does anybody know if you can take off the radiator from a 2002 Ford explore 4.6 without messing with the AC lines. If so is there any step by step instructions on how to do it
       
    13. imp

      imp Well-Known Member

      Joined:
      November 12, 2009
      Messages:
      3,385
      Likes Received:
      164
      Trophy Points:
      83
      City, State:
      Missouri Ozarks
      Year, Model & Trim Level:
      2004 XLT
      You, sir, are a gentleman and scholar!
       
    14. Black Dynomite

      Black Dynomite Active Member

      Joined:
      October 5, 2009
      Messages:
      263
      Likes Received:
      1
      Trophy Points:
      18
      City, State:
      Wellington, New Zealand
      Year, Model & Trim Level:
      2005 Ltd 4.6L
      2nd post above yours.....
       
      Elite Explorer members see practically no ads, can add their own profile photo, upload photo attachments directly to your posts and Media Gallery, create more private Conversations, and more. Join Today. Your support is greatly appreciated.


    15. Drewmcg

      Drewmcg Elite Explorer

      Joined:
      August 27, 2015
      Messages:
      294
      Media:
      8
      Likes Received:
      25
      Trophy Points:
      28
      City, State:
      Ann Arbor, MI
      Year, Model & Trim Level:
      2002 Explorer XLS 2WD
      I hate dealing with these radiators. I think removing /reinstalling the radiator on my '02 Exp.the first time I pulled the engine was one of the hardest part of the job.Replaced with one I bought from RockAuto which was cheap and works great. Second time I pulled the engine (to replace), I left the radiator in, protected by lots of cardboard.

      When I later replaced the a/c condenser with a used one (also works great), I found a video that showed how to do it without removing the radiator, which was a godsend.
       
      • Useful Useful x 1

    Share This Page







    We Support Our Troops!