While installing the Hutch Mod this past weekend, I noticed my radiator has started to leak. So it looks like I'll be doing my coolant system work sooner than I had planned:

1. Coolant system flush using Gooch's procedure and ELC.
2. Remove old radiator (Any good write-ups or advice appreciated)
3. Install new water pump. Original pump w/ 263K. Going to use Motorcraft OEM from Tousley's.
4. Replace thermostat and housing. 203F or 180F? Any thoughts on which is better?
5. Install new radiator - OEM from Tousley's or is there an upgrade? Can't afford Mishimoto.

Jim

 

If you can spare the extra cash I would install a coolant filter setup and never worry about it until the ELC needs to be changed at 300,000 miles!

I have a generic autozone radiator in my truck currently and have had no issues in the 10,000 miles Its been in there.

Have you tried getting an OEM international pump from Clay @ riffraff, his prices are hard to beat!

The only thing to watch out for on the rad is getting those transmission line fittings off without them breaking, they are not standard flare fittings!

As for the thermostat you will get many opinions on this, Do you want hot heat? then get the 203 but you need to drive the truck that much more to warm up. I am running a stock 195 with my mods and I have yet to have issues.

Make sure you replace the water neck inlet o ring as well, And apply a thin layer of RTV over the gasket surfaces on the front cover. Everything you will need is in the link below!

Riffraff Diesel: OEM Powerstroke Water Pump

 

Thanks for the info. Is there a special disconnect tool for the transmission line fittings?

Jim

 

Nope, I would pick up a set of line wrenches if you don't already have them. I would spray the fittings down with bp blaster or an equivilant and let them soak for a few days before. I have a cheapie set from autozone, the run about 12.00 a set. I went through the same issue with my rad, the lines broke off from rust and were sized into the fittings.

 

Here's a list of part numbers I compiled when I did my water pump last year. I used the reusable thermostat housing from Dieselsite, but had to seal it up with a little Permatex...those M6 bolts don't need a whole lot of torque applied to strip the threads from the pump...don't ask me how I know.

<table border="0" cellpadding="0" cellspacing="0" width="1127"><colgroup><col style="mso-width-source:userset;mso-width-alt:3766;width:77pt" width="103"> <col style="mso-width-source:userset;mso-width-alt:1243;width:26pt" width="34"> <col style="mso-width-source:userset;mso-width-alt:7570;width:155pt" width="207"> <col style="mso-width-source:userset;mso-width-alt:1060;width:22pt" width="29"> <col style="mso-width-source:userset;mso-width-alt:4498;width</colgroup><colgroup><col style="mso-width-source:userset;mso-width-alt:1060;width:22pt" width="29"> <col style="mso-width-source:userset;mso-width-alt:8886;width:182pt" width="243"> <col style="mso-width-source:userset;mso-width-alt</colgroup><colgroup><col style="width:48pt" width="64"> <col style="mso-width-source:userset;mso-width-alt</colgroup><colgroup><col style="mso-width-source:userset;mso-width-alt:3218;width:66pt" width="88"> <col style="mso-width-source:userset;mso-width-alt</colgroup><colgroup><col style="mso-width-source:userset;mso-width-alt:4681;width</colgroup><tbody><tr style="height:15.0pt" height="20"> <td class="xl66" style="height:15.0pt;width:77pt" height="20" width="103">Part Number</td> <td class="xl66" style="width:26pt" width="34">
</td> <td style="width:155pt" width="207">Alt. Part Number / Location</td> <td style="width:22pt" width="29">
</td> <td style="width Alt. Part Number</td> <td style="width:22pt" width="29">
</td> <td class="xl66" style="width:182pt" width="243">Description</td> <td class="xl66" style="width:20pt" width="27">
</td> <td class="xl65" style="width:48pt" width="64">Price</td> <td style="width:20pt" width="27">
</td> <td style="width:66pt" width="88">Location</td> <td style="width:19pt" width="25">
</td> <td style="width
</td> </tr> <tr style="height:15.0pt" height="20"> <td class="xl69" style="height:15.0pt" height="20">PW455</td> <td class="xl69">
</td> <td>F81Z8501FA</td> <td>
</td> <td class="xl67">
</td> <td class="xl67">
</td> <td class="xl69">Water Pump</td> <td class="xl69">
</td> <td class="xl70">193.65</td> <td class="xl67">
</td> <td class="xl67">Amazon</td> <td class="xl67">
</td> <td class="xl67">
</td> </tr> <tr style="height:15.0pt" height="20"> <td class="xl69" style="height:15.0pt" height="20">1815751-C1 </td> <td class="xl69">
</td> <td class="xl67">
</td> <td class="xl67">
</td> <td class="xl67">
</td> <td class="xl67">
</td> <td class="xl69">Water Pump Gasket</td> <td class="xl69">
</td> <td class="xl70">
</td> <td class="xl67">
</td> <td class="xl67">
</td> <td class="xl67">
</td> <td class="xl67">Came with Pump</td> </tr> <tr style="height:15.0pt" height="20"> <td class="xl69" style="height:15.0pt" height="20">1825293-C1</td> <td class="xl69">
</td> <td class="xl67">
</td> <td class="xl67">
</td> <td class="xl67">
</td> <td class="xl67">
</td> <td class="xl69">Heater Hose Fitting O-Ring</td> <td class="xl69">
</td> <td class="xl70">
</td> <td class="xl67">
</td> <td class="xl67">
</td> <td class="xl67">
</td> <td class="xl67">Came with Pump</td> </tr> <tr style="height:15.0pt" height="20"> <td class="xl69" style="height:15.0pt" height="20">F81Z8255AA</td> <td class="xl69">
</td> <td class="xl67">
</td> <td class="xl67">
</td> <td class="xl67">
</td> <td class="xl67">
</td> <td class="xl69">Lower Pipe Seal</td> <td class="xl69">
</td> <td class="xl70">5</td> <td class="xl67">
</td> <td class="xl67">Ford</td> <td class="xl67">
</td> <td class="xl67">Came with Pump</td> </tr> <tr style="height:15.0pt" height="20"> <td class="xl69" style="height:15.0pt" height="20">KDT3900</td> <td class="xl69">
</td> <td>T94T-6312-AH</td> <td>
</td> <td class="xl67">
</td> <td class="xl67">
</td> <td class="xl69">Pully Holder</td> <td class="xl69">
</td> <td class="xl70">18.49</td> <td class="xl67">
</td> <td class="xl67">Amazon</td> <td class="xl67">
</td> <td class="xl68">Rent if Necessary</td> </tr> <tr style="height:15.0pt" height="20"> <td class="xl69" style="height:15.0pt" height="20">KDT3473</td> <td class="xl69">
</td> <td>T83T-6312-B</td> <td>
</td> <td class="xl67">
</td> <td class="xl67">
</td> <td class="xl69">Fan Clutch Wrench</td> <td class="xl69">
</td> <td class="xl70">20.46</td> <td class="xl67">
</td> <td class="xl67">Amazon</td> <td class="xl67">
</td> <td class="xl68">Rent if Necessary</td> </tr> <tr style="height:15.0pt" height="20"> <td class="xl66" style="height:15.0pt" height="20">490218</td> <td class="xl66">
</td> <td>
</td> <td>
</td> <td>
</td> <td>
</td> <td class="xl66">Radiator Drain Petcock</td> <td class="xl66">
</td> <td class="xl65">2.73</td> <td>
</td> <td>Rock Auto</td> <td>
</td> <td>
</td> </tr> <tr style="height:15.0pt" height="20"> <td class="xl66" style="height:15.0pt" height="20">RS527</td> <td class="xl66">
</td> <td>
</td> <td>
</td> <td>
</td> <td>
</td> <td class="xl66">Radiator Cap</td> <td class="xl66">
</td> <td class="xl65">5.58</td> <td>
</td> <td>Rock Auto</td> <td>
</td> <td>
</td> </tr> <tr style="height:15.0pt" height="20"> <td class="xl66" style="height:15.0pt" height="20">F81Z-8260-CA</td> <td class="xl66">
</td> <td>KM4351</td> <td>
</td> <td>
</td> <td>
</td> <td class="xl66">Upper Radiator Hose</td> <td class="xl66">
</td> <td class="xl65">24.89</td> <td>
</td> <td>Rock Auto</td> <td>
</td> <td>
</td> </tr> <tr style="height:15.0pt" height="20"> <td style="height:15.0pt" height="20">YC35-8B273-CF</td> <td class="xl66">
</td> <td>KM4542</td> <td>
</td> <td>
</td> <td>
</td> <td class="xl66">Lower Radiator Hose</td> <td class="xl66">
</td> <td class="xl65">22.99</td> <td>
</td> <td>Rock Auto</td> <td>
</td> <td>
</td> </tr> <tr style="height:15.0pt" height="20"> <td class="xl66" style="height:15.0pt" height="20">JK81223AA</td> <td class="xl66">
</td> <td>
</td> <td>
</td> <td>
</td> <td>
</td> <td class="xl66">Serpentine Belt</td> <td class="xl66">
</td> <td class="xl65">33.79</td> <td>
</td> <td>Rock Auto</td> <td>
</td> <td>
</td> </tr> <tr style="height:15.0pt" height="20"> <td class="xl66" style="height:15.0pt" height="20">F81Z8592BA</td> <td class="xl66">
</td> <td>RH65</td> <td>
</td> <td>
</td> <td>
</td> <td class="xl66">Water Pump Lower Elbow</td> <td class="xl66">
</td> <td class="xl65">39.79</td> <td>
</td> <td>Rock Auto</td> <td>
</td> <td>
</td> </tr> <tr style="height:15.0pt" height="20"> <td class="xl69" style="height:15.0pt" height="20">
</td> <td class="xl69">
</td> <td class="xl67">
</td> <td class="xl67">
</td> <td class="xl67">
</td> <td class="xl67">
</td> <td class="xl69">Upper Thermostat Housing</td> <td class="xl69">
</td> <td class="xl70">54.35</td> <td class="xl67">
</td> <td class="xl67">Dieselsite</td> <td class="xl67">
</td> <td class="xl67">
</td> </tr> <tr style="height:15.0pt" height="20"> <td class="xl69" style="height:15.0pt" height="20">F4TZ8255A</td> <td class="xl69">
</td> <td class="xl67">THM1106</td> <td class="xl67">
</td> <td class="xl67">RG581</td> <td class="xl67">
</td> <td class="xl69">Thermostat Seal</td> <td class="xl69">
</td> <td class="xl70">0.89</td> <td class="xl67">
</td> <td class="xl67">Dieselsite</td> <td class="xl67">
</td> <td class="xl67">Came with Housing</td> </tr> <tr style="height:15.0pt" height="20"> <td style="height:15.0pt" height="20">F81Z8592AA</td> <td>
</td> <td>RH63</td> <td>
</td> <td>
</td> <td>
</td> <td class="xl66">Upper Thermostat Housing</td> <td class="xl66">
</td> <td class="xl65">19.76</td> <td class="xl67">
</td> <td class="xl68">Rock Auto</td> <td class="xl68">
</td> <td class="xl68">Unnecessary because of Billet Housing</td> </tr> <tr style="height:15.0pt" height="20"> <td style="height:15.0pt" height="20">
</td> <td>
</td> <td>RT1201</td> <td>
</td> <td>
</td> <td>
</td> <td class="xl66">Thermostat</td> <td class="xl66">
</td> <td class="xl65">29.52</td> <td class="xl67">
</td> <td class="xl68">Amazon</td> <td class="xl68">
</td> <td class="xl68">Newer Thermostat has gaskets on either side - RG581 unnecessary</td> </tr> <tr style="height:15.0pt" height="20"> <td class="xl69" style="height:15.0pt" height="20">1817817C1</td> <td class="xl69">
</td> <td colspan="3" class="xl67">(3) Thermostat Housing to Pump</td> <td class="xl67">
</td> <td class="xl69">M6-1.0x20 Flange</td> <td class="xl69">
</td> <td class="xl70">
</td> <td class="xl67">
</td> <td class="xl67">McMaster</td> <td class="xl67">
</td> <td>
</td> </tr> <tr style="height:15.0pt" height="20"> <td class="xl69" style="height:15.0pt" height="20">9R534</td> <td class="xl69">
</td> <td colspan="3" class="xl67">(5) Water Pump to Block</td> <td class="xl67">
</td> <td class="xl69">M8-1.25X30</td> <td class="xl69">
</td> <td class="xl70">
</td> <td class="xl67">
</td> <td class="xl67">McMaster</td> <td class="xl67">
</td> <td>
</td> </tr> <tr style="height:15.0pt" height="20"> <td class="xl69" style="height:15.0pt" height="20">1818231C1</td> <td class="xl69">
</td> <td colspan="3" class="xl67">(1) Water Pump to Block</td> <td class="xl67">
</td> <td class="xl69">M8-1.25x80</td> <td class="xl69">
</td> <td class="xl70">
</td> <td class="xl67">
</td> <td class="xl67">International</td> <td class="xl67">
</td> <td>
</td> </tr> <tr style="height:15.0pt" height="20"> <td class="xl69" style="height:15.0pt" height="20">1818693C1</td> <td class="xl69">
</td> <td colspan="3" class="xl67">(3) Water Pump to Block</td> <td class="xl67">
</td> <td class="xl69">M8-1.25x110</td> <td class="xl69">
</td> <td class="xl70">
</td> <td class="xl67">
</td> <td class="xl67">International</td> <td class="xl67">
</td> <td>
</td> </tr> <tr style="height:15.0pt" height="20"> <td class="xl69" style="height:15.0pt" height="20">1822888C1</td> <td class="xl69">
</td> <td colspan="3" class="xl67">(4) Pully</td> <td class="xl67">
</td> <td class="xl69">M8-1.25x12</td> <td class="xl69">
</td> <td class="xl70">
</td> <td class="xl67">
</td> <td class="xl67">McMaster</td> <td class="xl67">
</td> <td>
</td> </tr> <tr style="height:15.0pt" height="20"> <td class="xl69" style="height:15.0pt" height="20">1817956C1</td> <td class="xl69">
</td> <td colspan="3" class="xl67">(2) Lower Inlet to Water Pump</td> <td class="xl67">
</td> <td class="xl69">M8-1.25x20</td> <td class="xl69">
</td> <td class="xl70">
</td> <td class="xl67">
</td> <td class="xl67">McMaster</td> <td class="xl67">
</td> <td>
</td> </tr> <tr style="height:15.0pt" height="20"> <td class="xl69" style="height:15.0pt" height="20">FELCC7997G</td> <td class="xl69">
</td> <td class="xl67">Rotella ELC as Replacement</td> <td class="xl67">
</td> <td class="xl67">
</td> <td class="xl67">
</td> <td class="xl69">4 Gallons ELC Coolant Concentrate</td> <td class="xl69">
</td> <td class="xl70">
</td> <td class="xl67">
</td> <td class="xl67">International</td> <td class="xl67">
</td> <td>
</td> </tr> <tr style="height:15.0pt" height="20"> <td style="height:15.0pt" height="20">
</td> <td>
</td> <td>Permatex Ultra Copper</td> <td>
</td> <td>
</td> <td>
</td> <td class="xl66">
</td> <td class="xl66">
</td> <td class="xl65">
</td> <td>
</td> <td>
</td> <td>
</td> <td>Sealing between upper thermostat billet housing and pump / plus brass fitting on pump</td> </tr> </tbody></table>

 

The factory service manual calls for the water pump bolts to be torqued to something like 35 ft/lbs. That is WRONG! An error was made.

Proper torque value for the water pump retaining bolts is 18 ft/lbs.

Same is true for the two little bolts at the lower inlet pipe.

Heed!

Pop

 

So I ordered a replacement OEM radiator from Tousley's (online) for $225 after local dealer originally quoted $315. Tousley's called back yesterday afternoon saying they recommended I buy locally because they are having a lot of radiators damaged in shipment. I really appreciate their honesty!!!!

So I went back to the dealer and explained the situation. The parts manager dropped the price to $253, which I think would be less than what I would have paid with shipping cost.

Anyone have a link to a service manual for radiator replacement?

Thanks,
Jim

 

Well as luck would have it the transmission lines were seized to the fittings even after being sprayed with PB Blaster for three days. The fittings were easy to get out of the radiator but since the lines were seized they are now broke. Checked online at Tousley's, but they don't list them? Anyone have a part number??

Coolant flush done. Old Radiator is out. New water pump installed. Monday I'll take the lower hose outlet in to be blasted and powder coated. The 2002 outlet is short and straight not like the earlier models. Can't seem to find a new one online, so I'll just reuse the old one. Also will have to buy a new heater hose nipple, the old one is seized into the old pump.

Thanks,
Jim