Complete removal and replacement of the radiator assembly on a 2021-2024 Ford F-150 with 3.5L EcoBoost V6 engine, including coolant drain, fan removal, and hose disconnection.

Warnings

Tools required

Parts

• Radiator assembly × 1 — Use OEM specification
• Upper radiator hose × 1 — Inspect and replace if deteriorated
• Lower radiator hose × 1 — Inspect and replace if deteriorated
• Hose clamps × 4 — Replace if corroded
• Transmission cooler line o-rings × 2 — Replace if equipped with external cooler

Fluids

• Motorcraft Orange Coolant — 13 qt

Preparation

1. Ensure engine is completely cold to the touch
2. Disconnect negative battery cable and wait 2 minutes for system capacitors to discharge
3. Remove engine cover by pulling upward on four retention points
4. Place large drain pan under radiator drain petcock location on driver side lower tank
5. Raise vehicle on lift or support securely on jack stands if additional clearance is needed for lower access

Procedure

1. 1

   Drain cooling system
   Open radiator drain petcock on driver side lower tank by turning counterclockwise. Allow coolant to drain completely into pan. Remove radiator cap slowly to vent system and speed draining. Once drained, close petcock hand-tight only.
   Torque spec

   Drain Petcock5 Nm (4 lb-ft)
2. 2

   Remove upper radiator hose
   Locate upper radiator hose at right side of radiator. Use hose clamp pliers to compress spring clamp and slide away from radiator neck. Twist hose gently to break seal, then pull firmly to disconnect from radiator. Be prepared for residual coolant spillage.
3. 3

   Remove lower radiator hose
   Access lower radiator hose at bottom of radiator on driver side. Use hose clamp pliers to compress spring clamp and slide away from radiator outlet. Twist and pull hose off radiator. Allow any remaining coolant to drain into pan.
4. 4

   Disconnect transmission cooler lines
   Locate transmission cooler lines on passenger side of radiator lower tank. Use appropriate line disconnect tool to release quick-connect fittings. Press tool onto line while pulling line away from radiator. Cap or plug lines immediately to prevent fluid loss and contamination. Have drain pan positioned as ATF will drain out.
5. 5

   Disconnect radiator fan electrical connector
   Locate electrical connector on fan shroud assembly at top of radiator. Press release tab and pull connector straight out. Remove any wire harness clips securing harness to fan shroud or radiator.
6. 6

   Remove cooling fan assembly
   Remove four fan shroud mounting bolts securing fan assembly to radiator. Two bolts are at top of shroud, two at bottom. Lift fan and shroud assembly straight up and out of engine compartment as a single unit. Be careful not to damage fan blades on surrounding components.
   ⚠Fan shroud is integrated with electric fan motor. Handle carefully to avoid damage to fan blades or motor housing.
7. 7

   Disconnect auxiliary connections
   Disconnect any auxiliary hoses from radiator including coolant overflow hose from filler neck. Note routing and orientation for reinstallation. If equipped with engine oil cooler lines at radiator, disconnect using appropriate line tool.
8. 8

   Remove radiator mounting bolts
   Remove two upper radiator mounting bolts located at top corners of radiator support brackets. These secure radiator brackets to core support. Note use of rubber isolation mounts.
   ⚠Radiator mounts use plastic brackets. Do not overtighten bolts during reinstallation.
   Torque spec

   Radiator Mount Bolts12 Nm (9 lb-ft)
9. 9

   Remove radiator from vehicle
   Carefully lift radiator straight up and out of engine compartment. Radiator sits on lower rubber mounts and must be lifted clear of mounting pins. Tilt top toward engine slightly if needed for clearance past AC condenser. Inspect lower mount pins and rubber isolators for damage.
10. 10

    Install new radiator
    Inspect and transfer lower rubber isolators to new radiator if not included. Carefully lower new radiator into position, aligning lower mount pins with holes in core support. Ensure radiator seats fully onto lower mounts. Install upper mounting brackets and bolts, torquing to specification. Do not overtighten plastic mount components.
    Torque spec

    Radiator Mount Bolts12 Nm (9 lb-ft)
11. 11

    Reconnect transmission cooler lines
    Install new o-rings on transmission cooler line fittings, lubricating lightly with ATF. Push lines firmly into radiator fittings until an audible click is heard. Tug on lines to verify secure connection. If threaded fittings are used, torque to specification.
    Torque spec

    Transmission Cooler Lines25 Nm (18 lb-ft)
12. 12

    Install radiator hoses
    Install lower radiator hose first, ensuring it seats fully onto radiator outlet. Position hose clamp 1/4 inch from end of hose and torque to specification. Install upper radiator hose, seat fully, and install clamp. Ensure hoses are routed without kinks or interference.
    ⚠Do not overtighten hose clamps. Excessive torque can cut into hose and cause leaks.
    Torque spec

    Upper/Lower Hose Clamps3 Nm (2 lb-ft)
13. 13

    Reinstall cooling fan assembly
    Lower fan and shroud assembly into position, aligning mounting holes with radiator. Install four fan mounting bolts and torque to specification. Reconnect fan electrical connector and secure wire harness with clips.
14. 14

    Refill and bleed cooling system
    Close radiator drain petcock hand-tight. Install coolant funnel adapter on radiator filler neck. Pour Motorcraft Orange Coolant into funnel slowly until system is full and coolant appears in funnel. Start engine and allow to idle with funnel in place. Run heater on high setting. As engine warms and thermostat opens, coolant level in funnel will drop. Continue adding coolant to maintain level. Once engine reaches operating temperature and cooling fan cycles, squeeze upper radiator hose several times to purge trapped air. Add coolant as needed. When no more air bubbles appear and level remains stable, remove funnel and install radiator cap.

Reassembly

1. Reconnect overflow hose to radiator filler neck
2. Verify all hose clamps are properly positioned and torqued
3. Check that all electrical connections are secure and harness is properly routed
4. Reinstall engine cover by pressing down on four retention points until seated
5. Reconnect negative battery cable

Verification

• With engine at operating temperature, visually inspect all hose connections and fittings for coolant leaks
• Check transmission cooler line connections for ATF leaks
• Verify cooling fan operates when engine reaches normal operating temperature
• Confirm coolant level is at MAX mark on overflow reservoir when engine is cold
• Test drive vehicle and monitor temperature gauge for normal operation between 190-220°F
• Recheck coolant level after test drive and top off if necessary
• Inspect radiator drain petcock area for any seepage after test drive

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