Ford F3TZ-8005-A Radiator Assembly

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The cross-flow fin-and-tube design radiator in later model F-Series and Bronco vehicles has a vacuum-brazed aluminum core and nylon end tanks. The nylon tanks are molded with mounting brackets and attached to the aluminum core using tabs bent over the tank edge, creating a seal with an O-ring gasket. To replace or fix leaks between the tank and core, a home mechanic can follow these steps: open the tabs without excessive deformation, lift the tank, remove the O-ring gasket, inspect the core's seal surface, check and lubricate the new O-ring, position the tank on the core, clamp it with two clamps, tighten the header clamps to compress the O-ring gasket, squeeze the header tabs against the tank using locking-type pliers, conduct a leak test at 21 psi, and address minor leaks by further squeezing the tabs.

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.