Im trying to replace the radiator support on my 1996 f150,4.9. It was really bad shape. The problem I'm having today is trying to cut the old radiator support bushings or mount free from the frame. I cut the nut off at the top, where I was able to remove a square shaped washer, a shim, a thick spacer and another washer, but I can not get the bolt out of the frame support. The head of the bolt and washer is on the bottom side and a washer with a hexagon shape opening in the middle that slides over what looks like a hexagon bolt (?). Should I cut between the hexagon washer and the frame mount. I'm not sure if that is the answer either.

 

The bolt unscrews from the bottom. You might need to put PB Blaster on it for a few days to free it up. And you will probably need a impact driver also. Then I raised the body in front for make room for the bushing removal. Sandy

 

Thanks Sandy,

I tried to send to a response earlier, it didn't go.

I have tired that, I started spraying PB blasted on wednesday last, then tried the Mac Tool impact today, but it doesn't want any part of it. It just hammers. I would have thought it would have snapped by now, but no.

So Im back to either cutting out with a saw-zall, cutting under the washer. Die grinder, by segmented the washer on top and peeing it off then replacing the OEM washer with a standard washer. ( do I need to use the OEM washer?) or trying to drill it out.

Any recommendations?

 

I don't think cutting the washer is going to help and I wouldn't cut the bolt head. I believe you will have to remove the bolt because it is threaded up in there and the nut was just a back up. IIRC. Sandy

 

SO you don't think cutting the head of the bolt either would help? I'm sort of stuck. there has to be a way to get this bolt out of there.

 

. If it is threaded up in there that would give you nothing to use to get the bolt out. I'm almost positive it is threaded a lot up in there.

 

. Now that you have the nut off of the top maybe you can put some PB blaster up there and let it work its way down.

 

Not sure what I need to do here. I know I just put the impact back on it and it has been on there so much I have started to round the head of the bolt so it's not going to be useable to get it out. It would seem that is the head was off the bolt it should be free to pull out. I don't see what else could hold it tight. I would love to see the gem bolt to really understand how this is intended to work.

 

This piece is holding the bushing and you can see where it is threaded also. As you saw the bolt is threaded all the way to the top where the nut was. You almost have to use an impact socket to keep from rounding the bolt out, Sandy

 

Body Mounts - Gary's Garagemahal (the Bullnose bible)

Here's an illustration of how everything goes together.

 

Great pictures 1985 Bronco.....

 

Well, It can be cut out. Below is a picture of the bottom side of the heavy washer that captures the radiator support mounts. The round circle in the middle is the bolt, the inside hexes the heavy washer, the outside hex is another washer:
[img]blob:https://www.ford-trucks.com/2f1f9d35-624a-49c5-9a89-20b2b593ee42[/img]

Looking at the top side of the heavy hex washer that captures the radiator support mount;
[img]blob:https://www.ford-trucks.com/0411ba2f-637c-4ec7-b10d-fdbd6e7eeb6a[/img]

The bottom radiator support mount, below the frame support.

[img]blob:https://www.ford-trucks.com/aac4cc8a-3aa9-4da2-a6ce-6a7d4d833ece[/img]
The frame support. I cut the bolt/assembly as close to the frame support as I could. I didn't realize there was yet another washer next to the frame support, which made it a little difficult.
[img]blob:https://www.ford-trucks.com/b361b182-e234-4214-97c7-065371cf77a7[/img]

I used a 9" long reciprocating 18TP1 blade to cut. My truck has a lot more washers than what is defined. I have a total of 5 on each side, one is .50 thick.

The radiator support was really bad, I'm putting the new radiator support back with urethane mounts.

Thanks for everyone's help. Sandy...A special thanks to you for gather information for me.

 

Glad you got it out. In seeing that diagram I could tell it could be cut. It's been a long time since I was in there so I wasn't positive about cutting. I could not duplicate those bolts since they are so long and threaded to the top. I ordered them from Bronco graveyard and they come as a kit with bushings, bolts etc. I just looked at that diagram again. Read the part on the left about motion control about the distance between the support and bushing mount. Maybe that is why you have so many spacers. I'm going to check my distance tomorrow. I think I only had two per side but I put all mine back in. Sandy