Rotted Radiator Support
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Senior User
Joined: Apr 2004
Posts: 339
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From: north central Indiana
Rotted Radiator Support
Heard a new "popping" sound in the '90 F150 the other day, but couldn't isolate it. Found the cause tonight...the radiator support is totally rotted away just outside the RH mount on the framerail. The weight of the fender, battery, etc is flexing the whole right front corner of the doghouse! Looks like I've got some work to do.
Has anyone else had this problem? Is this a common rust-out area? Any recommendations as far as sources for new/aftermarket supports?
Has anyone else had this problem? Is this a common rust-out area? Any recommendations as far as sources for new/aftermarket supports?
Junior User
Joined: Feb 2002
Posts: 91
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From: Brunswick, Ohio
The rusted out radiator core support has been a staple in just about every Ford truck that I have owned from the early 80s to early 90s.
Replacement is a job that can take all weekend. Just about every screw in the grill will want to snap. Be prepared to replace lots of broken bolts including the long ones holding the core support to each frame rail. I have always had crumbling front rubber bushings and rusted bolts to replace and they aren't cheep. The last set I purchased from Ford cost me $100 and no one makes polyeurothane bushings for the front.
Replacement is a job that can take all weekend. Just about every screw in the grill will want to snap. Be prepared to replace lots of broken bolts including the long ones holding the core support to each frame rail. I have always had crumbling front rubber bushings and rusted bolts to replace and they aren't cheep. The last set I purchased from Ford cost me $100 and no one makes polyeurothane bushings for the front.
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Senior User
Joined: Apr 2004
Posts: 339
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From: north central Indiana
I've dealt with the rusted/broken bolt syndrome many times in 29 years of wrenchin' for a living. That part is "business as usual" for me.
I called "my guys" down at a local parts store yesterday and this morning they delivered a new aftermarket support assembly. Couldn't even find a decent "experienced" part. $200 delivered. No shipping and overnight. I might have found it cheaper online somewhere but wanted it this weekend, and would have had to pay for shipping, too.
The mounts appear to be in good shape, but I've been down that road a few times, too. I'm not even gonna plan on driving it to work Monday. While the doghouse is off I'm going to take care of some things on the engine (oil leaks) so there ain't no way I'm going to get that done in a day-and-a-half. Just hope I get it back together before we get another nasty winter storm. The Mustang just doesn't get around too good in that stuff....
Wish me luck!!
I called "my guys" down at a local parts store yesterday and this morning they delivered a new aftermarket support assembly. Couldn't even find a decent "experienced" part. $200 delivered. No shipping and overnight. I might have found it cheaper online somewhere but wanted it this weekend, and would have had to pay for shipping, too.
The mounts appear to be in good shape, but I've been down that road a few times, too. I'm not even gonna plan on driving it to work Monday. While the doghouse is off I'm going to take care of some things on the engine (oil leaks) so there ain't no way I'm going to get that done in a day-and-a-half. Just hope I get it back together before we get another nasty winter storm. The Mustang just doesn't get around too good in that stuff....
Wish me luck!!
Post Fiend
Joined: Oct 2003
Posts: 6,214
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From: New Jersey
there is a guy on e-bay, a1autoparts, that sells F-series radiator supports for under $100 (I think its $90 plus shipping, something in that ballpark anyway), and its really more intimidating to the eye than it really is.
Both fenders come off, the grill, lights, etc, lots of screws and trim pieces, disconnect the harness on both sides right at the radiator support, swap in the new one, bolt it in, reassemble, its a 10 hour job for an average guy with a phillips screwdriver and a Home Depot "Husky" socket set and several beers.
Its time consuming, but its not difficult. Make it easier and use small cans or ziplocs to put all the grill screws together, all the light screws together, the fender bolts together, etc, so you don't lose any or mix them up. Other than that, its just time.
If you're extremely cheap (er,frugal) like me, you'd take it all apart,and weld on two pieces of flat sheet steel on both sides, bent on the end of your workbench with a large framing hammer, to form a sorta "C" shape that cups thebottom of the radiator support both sides. Weld on, drill support hole for mount, bolt radiator support back in after you paint it.
Both fenders come off, the grill, lights, etc, lots of screws and trim pieces, disconnect the harness on both sides right at the radiator support, swap in the new one, bolt it in, reassemble, its a 10 hour job for an average guy with a phillips screwdriver and a Home Depot "Husky" socket set and several beers.
Its time consuming, but its not difficult. Make it easier and use small cans or ziplocs to put all the grill screws together, all the light screws together, the fender bolts together, etc, so you don't lose any or mix them up. Other than that, its just time.
If you're extremely cheap (er,frugal) like me, you'd take it all apart,and weld on two pieces of flat sheet steel on both sides, bent on the end of your workbench with a large framing hammer, to form a sorta "C" shape that cups thebottom of the radiator support both sides. Weld on, drill support hole for mount, bolt radiator support back in after you paint it.
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Laughing Gas
Joined: Jul 2004
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Was wondering how you made out or if you tried yet. Mine has rust starting there too. Is it all bolts or is there any spot welds anywhere... Thanks.....
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Post Fiend
Joined: Oct 2003
Posts: 6,214
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From: New Jersey
Originally Posted by Fair 96
Was wondering how you made out or if you tried yet. Mine has rust starting there too. Is it all bolts or is there any spot welds anywhere... Thanks.....
I've had a fair amount of the nose of my 93 crewcab off before, and I didn't see any rivets or spot welds tying the radiator support to anything else, but not having taken it completely off, I can't say for sure.
If there are spot welds, they'll be about 3/8" in diameter, which you can drill out with a hand drill since its thin mild steel, then when replacing the support, you can drill the new support and use a 3/8" bolt, two washers, and an aircraft nut in place of the spot weld. But again, I didn't see any welds or rivets.
While I have the nose off, and the engine out, I'm also going to take off the front suspension, dismantle it, and paint the frame, the suspension pieces, and make sure the firewall is solid (which it appears to be from what I can see so far), to protect these items going forward.
I'm shooting for another 300K miles
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Senior User
Joined: Apr 2004
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From: north central Indiana
Got the support pulled out today...took about 4 hours. Didn't have to remove the fenders to get the support out as I had thought. Only one small broken screw (rusted) and a few stubborn ones but no big deal really. Still have to deal with the severely rusted and seized mount bolts, though. One loosened enough to remove that side, and the other was rotted completely away so nothing was holding it on anyway...
I'll get back on it tomorrow and see how it progresses.
I'll get back on it tomorrow and see how it progresses.
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Senior User
Joined: Apr 2004
Posts: 339
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From: north central Indiana
Looks like there's going to be a slight delay in my project, due in part to awaiting the arrival of new support mounts and radiator, and because I have to go out of town on company business. Maybe Wednesday night I can get back to it.
Senior User
Joined: Dec 2001
Posts: 331
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From: Michigan
when you order those new rubber mounts be sure to order the bolts. The bolts come up from the bottom and are threaded the whole length of the bolt. When tightening the nut on top be sure to hold the bolt. I first tried this with a short socket and it backed the bolt out the bottom.
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Senior User
Joined: Apr 2004
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From: north central Indiana
Finally got back to work on truck this afternoon. In about five hours I have it almost back together. Had to slightly "modify" the new core support at the lower LH corner at the radiator opening. The lip around the opening had to be rolled over to clear the seam of the radiator tank. No big deal really. Aftermarket part so it wasn't unexpected.
Shouldn't take long tomorrow to finish it up. Overall, I'm pretty pleased with the way the job has gone. It takes some time but it's not that hard to do. The worst part was the rusted up mounts and bolts.
Shouldn't take long tomorrow to finish it up. Overall, I'm pretty pleased with the way the job has gone. It takes some time but it's not that hard to do. The worst part was the rusted up mounts and bolts.
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