Radiator Removal Lots of pics and step by step

[boggs0214]

After my trans cooler (inside radiator) busted i had to replace my radiator. After searching for a little while i saw that nobody has started a thread with pics and full instructions so i will be the first. Everything that has to be removed (nuts, bolts, clips) are either circled in red or has an arrow pointing to it. Whenever i was removing the radiator i referenced the technical maintenance manual (pdf file). I have 5 individual posts to make so please do not post any responses until the last step of the radiator being removed. Thanks

Tools Needed
drain pan
10mm socket
8mm socket
socket wrench
8mm wrench
10mm wrench
flat tip screw driver
crescent wrench
pliers (regular not needle nose)


Keep in mind that i was referencing the technical maintenance manual and i am translating that into my own words.

Step one

A) Remove the engine cover.........2 10mm bolts right in front.

B) Remove the air cleaner and air duct assembly.........unclip clips by air filter, unclip electical line that is connected to the assembly as well as the plastic retainer holding the wires, then unscrew the clamp holding the air assembly onto the throttle body.

C) Drain coolant from the radiator.............located underneath on the passenger side....make sure your drain pan is underneath and that the coolant is hot

[boggs0214]

Step Two

A) Disconnect the automatic transmission fluid cooler hoses.........there are two clamps that the bottom of the radiator (one on driver one on passenger). Note - if you would like to keep your transmission fluid be sure to clamp the two hoses so the fluid doesnt leak out

B) Disconnect the radiator upper and lower hoses........upper is under the hood on the left of the radiator cap and the lower is underneath on the passenger side.

NOTE - all fluid will not be removed from the radiator so whenever you are disconnecting the lines ensure that you have something to catch the fluids with.

[boggs0214]

Step Three

A) Remove the lower radiator shroud.....three clips located underneath....once they are uncliped move shroud towards fan and slide downward

B) Remove the upper radiator shroud bolts..........move shroud towards fan and pull up

[boggs0214]

Step Four

A) Remove the the air condition condenser bolts and brackets.........there are two located underneath a plastic covering.....pull the covering back to expose and try not to lose the bold.....kind of tricky if you have large hands.......also ensure you locate the brackets because they are just pressed in with rubber gromets

[boggs0214]

Step Five

A) Remove all lines from the radiator.......the one on the right in the picture was hiding from me so i snapped a picture of it.....it is right by the coolant resivor (passenger side)

B) Begin to slide the radiator out........you will see that the a/c condenser will get bound up on the radiator when trying to remove it......i just simple asked the wife to reach into the lower bumper inlet and pull it towards her and just wiggled it out.

C) Remove the external radiator cooler from the radiator itself........two bolts on to and slides into grooves at the bottom.

Note - You can see that i took the radiator out with the fan still installed.........it can be done but scraped up the fins on the radiator as you can see in the picture so i would suggest that you remove the fan as well. The fan removal must be done with a 10mm wrench and has 4 nuts holding it on. I didnt snap a pic of it but they are gold.....you cannot miss them




I have actually never replace a radiator before but i am pretty mechanically inclined so i tried to make this HOW TO post the easiest that i could for almost anyone the remove their own radiators and not get caught at the dealership paying over $1000 for the parts and labor. Hopefully this will help everyone out that has already order the all aluminum Stillen radiator and that have to wait like myself. If I recall it took me about an hour to do the whole process, take notes on everything, and take pictures. Without doing all that it probably would have taken me 30 minutes. This is actually a really simple process and with the right tools I just gave you all the information that you need to accomplish it.

[themaildude]

Thanks for the write-up with pics.

[boggs0214]

thanks for waiting until i was done.....i didnt want anyone to have to go searching through posts and replies looking for all the steps

[RobKar]

Nice ... ....

[roy365]

Thanks a lot!!!!

Pictures are always good!!!!!

[Kronos1965]

Well-documented and detailed from a "regular" guy.

Very much appreciated as I will be buying a Stillen radiator at the first of the year...

[HRTKD]

Nice writeup! So the Stillen radiator won't get to you until next month, right?

[titanss]

Great Write Up!!!

[travelship]

Very nice writeup, I'm bookmarking this thread for when I need it.

Originally Posted by boggs0214

thanks for waiting until i was done.....i didnt want anyone to have to go searching through posts and replies looking for all the steps

You could just make 5 quick posts when you start the thread, and then go back and edit them to add the info.

[loufish]

First off. great job!...Good pics also...
Second...did you notice how big the Titan radiator is?
Same goes for the trans cooler....that is a big cooler!

[walleeme]

Nice write up.
Thank you.
A couple months ago now, my buddy changed out the radiator in his 04, and he said it took kin 6 hours.
Just waiting now, until I have to do mine, or one of my buddies.
I bookmarked the thread in my favorites.