How to Replace a Ford Windstar Radiator

Over time radiators rust internally due to acidic and corrosive coolant that has remained in the cooling system for longer than it should have. When the radiator rusts, it could cause a leak, rendering the radiator useless. When driving, rocks can hit the radiator, puncturing it and also causing a leak. There are many products on the market designed to fix radiator leaks, but none of them works well. To fix a leaky radiator, the best option is to replace it. To replace your Ford Windstar radiator, follow the steps below.

Things You Will Need:

• New radiator
• Coolant
• Ratchet
• Sockets
• Flat head screwdriver
• Drain pan

1. Allow the engine to cool down

Allow the engine to cool down to avoid getting burned by the coolant.

2. Place a drain pan underneath the radiator

Place a drain pan underneath the radiator and open the drain plug. Allow the coolant to drain from the radiator.

3. Remove the upper and lower radiator hoses

Remove the upper and lower radiator hoses by loosening the hose clamps with a flat head screwdriver. Then pull the hoses off the radiator.

4. Disconnect the radiator fan connectors

Disconnect the radiator fan connectors and place them to the side.

5. Remove the radiator fans from the radiator with a ratchet

Remove the radiator fans from the radiator with a ratchet. There are two fans, and each one is held on by four bolts.

6. Remove the radiator with a ratchet

Remove the radiator with a ratchet. There are four bolts holding the radiator to the radiator core. Pull the radiator out of the engine compartment and replace with the new radiator.

7. Tighten the bolts for the new radiator

Tighten the bolts for the new radiator with a ratchet.

8. Reinstall the radiator fans with a ratchet

Reinstall the radiator fans with a ratchet and reconnect the electrical connectors.

9. Reconnect the upper and lower radiator hoses

Reconnect the upper and lower radiator hoses to the new radiator and tighten the hose clamps with a flat head screwdriver.

10. Fill the radiator with coolant

Fill the radiator with coolant.

Tips and Warnings

The radiator hoses can be very difficult to remove. To aid in removal, place a screwdriver between the radiator hose and the radiator and pry gently all around the perimeter of the hose. Twist the hose left and right and then pull back.

Wear safety glasses to protect your eyes from injury.

Video showing how to replace a Ford radiator:

Comments on this video:

• I tried doing it your way but that wasn't working. The trick to this is to remove the fan first. Take out the top transmission cooler line and two screws and the fan comes out from under. Also one key part that you missed, is telling us that the top left and right side of the radiator sits on top on the condenser. You cant just pull down on the radiator. In order to get just the radiator out you have top push up and over the condenser then it will come down. To get it back in put the radiator in by it's self leave all the lines and hoses off. Put the fan back on then the cooler lines. Your right it is ford engineering. Good luck!
• I jacked it up about six inches. Supporting the condenser with mechanics wire per the manual is very important! For installation using mechanics wire on both sides of the radiator up to above the cross member works well. Attach the wire holding the new radiator to a 2X2 or 2X4 on the top and lift the assembly in place with the 2X4. You can twist the 2X4 like a pulley to slowly lift the assembly. That made the job much easier, especially the part of getting the condenser attached to the radiator. Another idea, if you remove both headlights, there are two bolts on each side behind the headlights to remove the entire grill and bumper. That gives a lot more room under the vehicle to get at the hoses and lines and fasteners and removing and installing the grill-bumper is only a few minutes time.