My radiator support is rotted out. Not too bad but I don't want it to get worse. What do I need to buy to replace it besides tools, like new bushings and mounts???? How do I disassemble the front end? Is it easy to do or should I just save up and pay my garage to do it? Just I hate it rusting out

 

The rad support holds virtually the entire front end together and rests on the frame, it is an immense job. You must remove all the headlight assemblies and grill, then the plastic valance it is held on too. Someone must correct me here but I believe you also have to remove the fenders. Then the radiator must be removed, disconecting the hoses (which should be replaced) which also means a radiator flush to remove the fluids. Basically your truck has to look like this:


What I did, when we removed the the headlight assemblies we cut metal and folded it to make it doubleplated and then was welded over the rust spots. Then we undercoated the crap out of it and sprayed white grease over it. Hope this helps.

 

exactly what i was looking for thanks

 

I do not know if it is the same for a 1990, but I did not remove my fenders on my 1993. The hardest part for me was removing what was left of the 2 bushings. I used a angle grinder on them.

 

i'm in the process right now of replacing rad support for my 1987 250. i think its same design as 1990.

i got the old one out without taking off headlights or fenders, tho i haven't got the new one back in yet. took off the plastic grill, battery tray, radiator. also the little brackets at top left and right of rad support. my neighbor cut a badly rusted support bracket off with a torch. looked like over the years the battery leaking on the rad support and this bracket, that's what caused the rust.

anyway it really wasn't too hard to get the old one out with some help cutting off the bolt that hold the support bracket to the support itself. the other bolt was nice enough to snap off for me. the was the hardest part.

depends on your patience and tolerance for snapping a few connectors that you'll likely then have to replace. i was quoted $1,000 on mine a few years ago at a garage, in hindsight maybe i should have paid them. have about 350-400 in parts, but am replacing some other items now that i have it open.

 

Hey I am replacing my bushings with The polyurethane ones and would like to know if anyone has done this and has pictures