Cracked and Blocked radiator repair

[Godzilla]

Last few weeks i noticed the water level dropping on the old Ford.

On closer inspection i found that the plastic side tank had a hairline crack and was leaking near the top inlet hose.

2 years ago the same thing happened but on the other sides tank, i just went to a wreaker and picked up another for $80 to keep going but stored the old radiators good tank just incase this happened again on that tank.

I thought what the hell, ive got a day off work so ill give it a go.

Started to pry the locking tabs that hold the side tank with a screw driver and remove the tank.


When removing the tank 2 or 3 cup fulls of sand fell out that was sitting blocking the bottom third of the radiator. Ive heard that Ford had a problem with sand remaining in the heads after casting at the factory which blocked many radiators.
This is what didnt fall to the floor, note the core blockages.
Yes the bottom third was totally blocked.



Wire brushed all the crap, reverse flushed and ran wire through the passages till it was all out and water flowed through all the passages.
Put some Stag joining paste on the rubber seal, silicon would have also done the job.


Put the good side tank on and gently hammered the tabs that hold it all together back over taking care not to crack the plastic tank.


With a pair of multigrip pliers bend down the tabs firmly.


A lick (spray) of black paint and one recod radiator with no leaks.


She now no longer leaks, the thermo fans use to take about 2 minutes of running to cool her down, now its about 30 to 40 seconds.

Oh and just for the record a new one is only $200 to $240, but what the heck i was bored today.....

[best4less]

Not a bad days work mate
I always thought that sludge was the alloy heads slowly corroding away
Good old Ford

[Godzilla]

I always thought that sludge was the alloy heads slowly corroding away

Dont laugh what you see on the tubes is exactly that.
Just shocked by the amount of casting sand that fell out when i took the side tank off.
You would think Ford would clean it all out before assembling the engine.

Casting sand blocking the bottom half in some cases all over the Ford forums, people driving E series cars are keeping radiator shops nice and busy.
All you read about is "help my cars overheating".

If its not sand blocking the radiator, its the clutch fan failing or the special double action thermostate.

I through the clutch fan out last year and converted to the EL thermo fans with 4 relays and the car feels "free reving".

Cheap to run and buy parts for, but you spend all your time fixing them.
What can i say?.....Shit boxes.