Aluminum cooling on the cheap!

As posted by Cmonster Items needed:

• 96-98 rad. out of a V6 w/auto Ford Exploder.
• Upper radiator hose from same year Explorer.(fits perfect!)
• Stock lower radiator hose(fits perfect!)
• Mounting hardware: 4 bolts, but you will have to Guess and check. I had extra bolts/etc in the garage. not sure of the exact size. at leat 1 1/2"X 1/4"

Follow these steps for installation: First, with the new Explorer radiator, you will need to do some modification before install.

1. The plastic "triangle" on the bottom edge of the passenger side tank will need to be notched. Remove the front (closest to engine) portion of the triangle (leaving the back-side and bottom) with a dremel or something similar. Be careful not to damage the plastic tank!
2. Drain & remove old radiator, and disconnect all tranny lines etc.
3. Mock up the new unit by installing the upper radiator hose on the water neck at the block, and then slide it over the neck on the radiator.
4. The triangle on the drivers side should rest pretty close the the frame-rail on the passenger side, but I believe there is a brake line there. I just held mine above it by 1/8", (OR, just line the top of the new radiator up even with the top of the core support.)
5. If your factory battery tray is still in place, put the drivers side tank on the radiator about 1" from the inside edge of the tray.
6. With a buddy holding the rad in place, use a center punch to mark your new mounting holes for the two top rubber isolated mounting points.
7. Bottom mounting holes: Same as above ( I only used 3 mounting points: Two top holes, and passenger side "triangle")
8. Trans cooling lines: Remove the old fittings from the tank (be careful when removing these fittings! Use two wrenches to remove, as one puts too much stress on the plastic tank) I cant recall which cooling line is which as far as in/out go, you will have to check you service manual.
9. Take the old fittings to your local Home Depot/Lowes and go to the plumbing dept. Find the necessary brass fittings that will work for you. There may be a better way to do this than what I did, so I will let you decide which combo works.
10. You may need a new spacer to put the fan closer to the rad. for more efficient air flow. I got mine from a junkyard Caddillac.
11. Install new rad, trans lines, hoses etc. Double check fan placement (1" +/- from radiator), Check and Double check mounting points and make sure they are secure! I had one bolt come loose and the radiator swung into the fan, DOH!)
12. Fan shroud: I dont have one, sorry.
13. Fill coolant/water. check for leaks
14. Drive and enjoy your Big Block C, knowing now that you can sit in traffic with no worries! (unless you have other problems with your cooling system)!

I use a 160 deg thermostat/Milodon hi-flow water pump. In the middle of summer, I intentionally sat in traffic for an hour, and my temp never passed 185

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