Being Ambitious: Advice on Replacing Radiator & Related Components

[BootyDo]

Hi All,

I've had my 2006 4.6L V8 for several years now. I purchased it about 4-5 years back with 72K and I've added maybe another 20K on that. Long story short, I've been fixing and learning a lot because of this truck. Now I'm faced with having to replace my radiator - something I didn't think I'd even want to consider a few years back - and was wondering about some input.

First, the background. My radiator's been leaking for maybe 2 years or so. Bars Leak hasn't done much - mainly as of late - and I'm dumping about a gallon of coolant a week into it. It would be straightforward at that point, but I also have the dreaded jet fighter fan. I've read up on the TSB 7-10-12. Sounds a lot like my issues, (including a stuttering in the transmission at 1500rpm in 3rd/4th). After reading through several threads - mostly this one - I'm also considering playing it safe and replacing the 1) radiator, 2) water pump, 3)serpentine belt, fan clutch, and 5) thermostat. That's a lot. And I'm a dude that's dropped a few pans, swapped some brakes, fuel filters, intakes, etc. Nothing to this scale.

So with that said, I wanted to ask specifically for anyone's input on doing all this. Specifically, are there any special tools I'll need? Any parts I should steer clear of? I've watched FordTechMakuloco's great video on this. Just confused about the fan clutch. And having never done as much as a serpentine belt, I want to try and anticipate as many obstacles as I can on the front end and do this once and correctly. Also, any way of finding out what version my PCM is currently updated to?

Just a bit of disclaimer: My truck is throwing a rear wheel speed sensor. Not sure if it's just the sensor or a tone ring. If it's the ring, i'll take it to the dealer. And I think my front driver's side wheel bearing might be going bad. With the PCM, that's 3 pretty big expenses I'm likely leaving to the pro's so that's why I'm being a bit neurotic with this.

 

[Explorer_PL]

See the post below. Not very easy but doable. You need specific size spanner wrenches to remove the fun clutch. It needs 1 solid push to loosen up and it comes off. Replace both hoses and thermostat at the same time, and of course the fluid, don't use the old one.
Transmission lines are tricky to remove, you need special "quick disconnect" tools for that, I used a set from AutoZone, they come is set of 4 in different color and sizes. I think you need 1/2 inch one.

http://www.explorerforum.com/forums...t-a-radiator-for-2006-v8.378378/#post-3149175

The front bearing can be replaced fairly easy, the rear tone ring is more complicated.
If the water pump is not leaking, don't touch it.

 

[BootyDo]

Thanks Explorer_PL! Odd you mentioned not doing the water pump. Everyone else, (no one that actually owns an Explorer), keeps saying "you mind as well do it all."

For the radiator though, what exactly do i need?
Radiator
Coolant/Anti-Freeze, (was going with the one in the video)
Upper Radiator Hose
Lower Radiator Hose
Fan Removal Tool
Thermostat
Thermostat O-Ring
Transmission Removal Tool

Besides basic hand tools, does that sound like everything? I'm curious about the Thermostat. I've seen some Stants rated at 180, 192, and 195. What's the correct choice? And do I need to remove the entire thermostat housing or just swap out the old thermostat & O-Ring?

Thanks!

 

[willied]

I ended up replacing my radiator and fan clutch last year after having the same symptoms as you. I didn't replace anything else so I can't comment on the rest. The fan clutch was surprisingly easy to replace. I initially rented the fan clutch tool from Advance Auto Parts, but it didn't work (it just slipped over the nut) and I read reviews of others saying the same. I took those tools back and then rented some from O'Reilly. They worked just fine. I bought a tool to remove the trans lines but couldn't get them off so I just removed the bolts that connect to the trans lines and reused them.

The stuttering you mention sounds like you might need to get your trans fluid and filter changed. Have you had that done yet? I had the stuttering and getting the trans fluid changed fixed it.

 

[BootyDo]

I ended up replacing my radiator and fan clutch last year after having the same symptoms as you. I didn't replace anything else so I can't comment on the rest. The fan clutch was surprisingly easy to replace. I initially rented the fan clutch tool from Advance Auto Parts, but it didn't work (it just slipped over the nut) and I read reviews of others saying the same. I took those tools back and then rented some from O'Reilly. They worked just fine. I bought a tool to remove the trans lines but couldn't get them off so I just removed the bolts that connect to the trans lines and reused them.

The stuttering you mention sounds like you might need to get your trans fluid and filter changed. Have you had that done yet? I had the stuttering and getting the trans fluid changed fixed it.

Thanks willied! I was actually going to buy the fan clutch tool if the price was around $30-$50 just so I can take my time and do all this, (will likely be a lot of stop and starting over the course of a 5-day weekend with some family obligations). But I can't seem to find the right one. According to the video, it's 36mm. I think this one from Lisle would work but man that's pricey! If i wind up doing the water pump down the line, awesome. I get two uses out of it. But a single use for something I could rent...?

But it's funny you mentioned the clutch. i was going to let that go but sat in my driveway today after a long drive home. Coolant was about 194ish. In park, I put my AC on for 2 minutes. Temps went up to about 197ish. Tapped the gas and definitely got the jet fighter fan. So maybe it really is the clutch not disengaging.
So I'm back to doing the radiator, fan clutch, and thermostat.

Besides the fan removal tool, is it also necessary to get a new radiator cap? And does anyone know if I also need a new thermostat housing or just the thermostat and little washer ring?

Oh, and the transmission - YES! I'm not sure when the last time it was changed was, but after this project, i was going to change it anyway. Thinking back on it, the hesitation really wasn't there the first few years i had it. So if that's really all that's wrong, I will be so relieved! After that, I'm making my way to the brake pads & rotors and flushing the brake system. Then with everything out, replace the rear speed sensor and checking if the tone ring is cracked. Finally, going to have the PCM updated and I should be all caught up. Well, differential fluid change too I guess. Still...

 

[willied]

No problem!

Maybe you already know, but the rental from Advance or O'Reilly is free as long as you return it in time. Advance lets you rent stuff for 30 days I think and O'Reilly was only like 2 days, but since I only needed it briefly and the one from Advance didn't work...

As far as the fan clutch goes, mine did just start out making a lot of noise with it not overheating, but after a while it finally decided to give up I guess and it started to overheat. I had to drive with the heat on the day it started overheating and it wasn't cold outside...haha.

The radiator cap...do you mean is it necessary to get a lower PSI cap? I personally just went with an aftermarket radiator (TYC 2816) and am using the cap it came with. I know some people have mentioned using a lower PSI cap with the stock radiator.

FordTechMakuloco has a video on the 6R60 trans that talks about his recommended trans oil change intervals. They're a lot more often than Ford's crazy 150k oil change interval. And yeah, I watched his radiator replacement video as well - otherwise I don't think I would've done it myself. I wish he'd do a video on replacing the exhaust manifold - my right one needs replacing and I've heard it's a bit of a tough procedure.

 

[Partsman109]

I wish he'd do a video on replacing the exhaust manifold - my right one needs replacing and I've heard it's a bit of a tough procedure.

Here you go!...

 

[Partsman109]

I have a very similar list...I plan to do a cooling system overhaul too!
I also need to change the trans fluid, front and rear diffs and transfer case.

 

[willied]

Here you go!...

What the heck! How did I not see that? haha I guess I haven't checked in a while.

Thanks!

 

[Explorer_PL]

Look for a post started by me. I replaced both sides, took me 2 days, a day each.
My water pump was still good at 200k so that's why I said to leave it there.

I found it

http://www.explorerforum.com/forums...ds-replacement-on-4-6-v8.416927/#post-3354454

 

[BootyDo]

Hi All,

Just wanted to post a follow-up. First, thank you all for the great advice! I was able to swap out my old radiator for a new Spectra. It was a beeeotch. But I did it! In addition to the radiator, I disassembled and thoroughly cleaned everything that needed to be removed with some Super Clean, (if you've never used that stuff, it's a game changer!). I also replaced my fan clutch, replaced the thermostat/gasket, (that was a real pain w/o a ratcheting wrench), replaced my accessory belt, and swapped my upper radiator hose and radiator cap with new ones. Unfortunately, I could not get the transcooler hoses out so I had to unbolt the connection and swap it to the new radiator. And short of having a lift, I couldn't get the lower radiator hose out either

All that said, if anyone is thinking of doing this, have plenty of patience. The worst part for me was physically removing and putting the radiator in. I don't have a large wingspan so I had to hold it from the top, (as opposed to using one arm to wrap the bottom and shift hoses out of the way).

As for where I stand now, and definitely looking for a bit more advice, how to I know if I still have air in the system? According to the service manuals, the coolant capacity is just under 4 gallons. But I barely put in 2. Is that much stuck in the engine block? I started it, ran the heater on high, and it still didn't want to take much more. And lastly, the transmission. I really didn't anticipate losing that much fluid via the cooler lines. I picked up a quart of Mercon SP and the grease gun tool. But how do I know how much to put in w/o running the car hot? I also ordered 12 more quarts and a new filter so I'll be looking to drop the pan soon, but just wanted to ensure I didn't do any damage in the meantime.

Thanks again!

 

[willied]

Glad to hear you got it done!

I used one of these to burp the system, but I don't remember how much coolant I put in: https://www.amazon.com/Lisle-24680-...8&qid=1467853226&sr=8-1&keywords=lisle+funnel

Basically you keep putting coolant in it while the cars running until it's no longer bubbling. After you get that done go out for a drive and make sure it runs at the right temperature. And just keep an eye on the coolant level for a little while after to make sure it's not low.

As for the trans fluid...I lost some as well, but I didn't do anything about it...haha. I should probably check on that. Here's a video on it: