How to: 2002 Explorer Radiator Removal/Installation

1. Remove the upper air deflector.

2. Detach the A/C tube from the retainers.

3. Remove the inner air deflector.

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

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

6. Remove the radiator upper fan shroud.

7. Drain the cooling system.

Removal (cont)

8. Raise and support the vehicle.
9. Disconnect the cooler lines if equipped.
a. Remove the safety retainers from the connectors.

b. Use the special tool to disconnect the quick couplers.

c. Loosen and remove the screw clamp from the hose.
10. Disconnect the hose from the radiator, detach the hose from the retainer(s) and position it aside.

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

12. Remove the bolts and the lower fan shroud.

13. Disconnect the lower air dam pushpins.

14. Lower the vehicle.

Removal (cont)

15. Disconnect the degas bottle hose and upper radiator hose.

16. Remove the two bolts and the right radiator support bracket.

17. Remove the two bolts and the left radiator support bracket.

18. Remove the right A/C condenser support bracket.

19. 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.
20. Remove the radiator up and off the mounts and set it on the frame.
NOTE: RH side shown, LH side similar.

Removal (cont)

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

22. 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.
23. Using mechanics wire, support both sides of the A/C condenser.
NOTE: LH side shown, RH side similar.

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.
24. Remove the radiator and trans cooler as an assembly

Radiator disassembly

If radiator is being replaced:

25. Remove the bolts and the trans cooler.

26. Remove the splash shield pin-type retainers.

27. Disconnect the hose.

28. Remove the four bolts and the bracket.

NOTE: RH side shown, LH side similar.

Radiator assembly

If radiator is being replaced:

1. Position the bracket and install the bolts. (9 lb-ft)
2. Connect the hose using an appropriately sized worm drive-type clamp in place of the constant tension clamp.
3. Install the splash shield pin-type retainers.
4. Install the trans cooler and bolts. (89 lb-in)

Radiator Installation

5. Set the radiator assembly on the frame.
6. Remove the mechanics wire from the A/C condenser and position the condenser onto the lower mounts.
7. Install the right inner A/C air deflector shield.
8. Install the left inner A/C air deflector shield.
9. Align the lower mount and install the right A/C condenser mounting bracket. (89 lb-in)
10. Align the lower mount and install the left A/C condenser mounting bracket. (89 lb-in)
11. Set the radiator assembly onto the support mounts.
12. Install the right radiator support bracket and the two bolts. (9 lb-ft)
13. Install the left radiator support bracket and the two bolts. (9 lb-ft)
14. Raise and support the vehicle.
15. Install the lower front air dam pushpins.
16. Install the lower fan shroud and bolts. (62 lb-in)
17. Connect the left lower radiator hose using an appropriately sized worm drive-type clamp in place of the constant tension clamp.
18. Connect the hose to the radiator, and attach it to the retainer(s).
Use an appropriately sized worm drive-type clamp in place of the constant tension clamp.
19. Connect the trans cooler lines.
If equipped, install the safety retainer on the connector.
If equipped, install the screw clamp on the hose.
20. Lower the vehicle.
21. Install the upper fan shroud.
22. Install the bolt on the left side of the fan shroud. (62 lb-in)
23. Install the bolt on the right side of the fan shroud. (62 lb-in)
24. 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.
25. Install the inner air deflector.
26. Attach the A/C tube to the retainers.
27. Install the upper air deflector.
28. Fill and bleed the cooling system.
29. Fill and check the transmission fluid.