If the radiator on the Ford Windstar leaks or becomes clogged, you must replace it so the vehicle does not overheat. The heads are made of aluminum and warp easily when the engine overheats. You can reuse the engine coolant if it is less than five years old and clean. If you must discard it, do so in an appropriate manner. Use extended-life antifreeze when replacing the coolant. Extended-life antifreeze, made to last longer between changes, comes recommended by many aluminum part manufacturers, such as those who manufacture water pumps.
Slide the drain pan under the radiator petcock. Loosen the petcock, and allow the coolant to drain. Unhook the grill opening pushpins using your fingers. Disconnect the cooling fan motor wiring harness connector. Unbolt and remove the cooling fan assembly using the appropriate socket or wrench.
Slide the second drain pan under the transmission cooler lines. Remove the lines using the appropriate line wrench. Block the lines with a rag so transmission fluid doesn't continue to leak.
Loosen the clamps on the overflow hose, upper radiator hose and lower radiator hose with a screwdriver. Pull the hoses off the radiator. Remove the headlight mounting clips, also with a screwdriver. Remove the turn signal lamp retaining nuts using the appropriate wrench. Move the turn signal and headlight out of the way to gain access to the mounting bolts.
Remove the eight grill opening panel bracket bolts -- four on each side. Remove the hood latch support mounting bolts using the appropriate socket, then pull the support forward. Remove the radiator mounting bolts using the appropriate wrench.
Remove the six grill opening reinforcement screws -- three on each side. Lift the radiator grill opening panel reinforcement from the vehicle. Remove the top condenser mounting screw using the appropriate socket. Lift up the condenser while pushing down on the radiator to disconnect the clips on the bottom. Lift the radiator out of the vehicle.
Slide the new radiator into place. Position the condenser into place. Install the top mounting screws, and tighten them to 90 inch-lbs.of torque with a torque wrench. Reinstall the grill opening panel reinforcement screws, and tighten them firmly. Reinstall the radiator mounting bolts, and tighten them to 50 inch-lbs. of torque.
Reinstall the hood latch support, and tighten the mounting bolts to 20 foot-lbs. of torque with a torque wrench. Install the radiator grill opening panel brackets, and tighten the screws firmly. Reinstall the turn signal and headlight. Tighten the turn signal screw to 50 inch-lbs. of torque. Press in the headlight mounting clips.
Reconnect the transmission cooler lines at the radiator. Reconnect the overflow and upper and lower radiator hoses, then tighten the clamps. Reinstall the cooling fan motor assembly, and tighten the bolts to 90 inch-lbs. of torque. Plug in the cooling fan wiring harness connector.
Reinstall the grill opening panel pushpins. Close the petcock. Refill the radiator with coolant. Start the vehicle, leaving the radiator cap off. When the thermostat opens, the coolant level will lower -- top it off as needed.
