Ford F3TZ-8005-A Radiator Assembly

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The cross-flow fin-and-tube design radiator found in later model F-Series and Bronco vehicles features a vacuum-brazed aluminum core and nylon end tanks. The nylon tanks, molded as one piece with mounting brackets, are attached to the aluminum core using tabs bent over the tank edge, creating a seal with an O-ring gasket. To replace or address leaks between the tank and core, a home mechanic can follow these steps. Using a screwdriver or specialized tools, open the tabs without causing excessive deformation of the header side. Lift the tank, remove the O-ring gasket, and inspect the core's seal surface for cleanliness. Check and lubricate the new O-ring before placing it in the header groove. If replacing the outlet tank with an oil cooler, transfer it to the new tank. Position the tank on the core, clamp it with two clamps, and tighten the header clamps to compress the O-ring gasket. Use locking-type pliers to squeeze the header tabs against the tank, rotating the pliers while maintaining a specific assembled height. After removing clamps, squeeze additional tabs and conduct a leak test at 21 psi, addressing minor leaks by further squeezing the tabs in the affected area.

Remove the bolts that attach the fan shroud to the radiator support. Place the shroud over the fan, allowing space for radiator removal. In some cases, the fan itself may have to be removed.