CSF 3-core TJ radiator install

Jeepin Jason · 12-29-2005, 11:15 PM

Since our TJ has yet to roll 30k on the ticker I really hadn't given the radiator and coolant much thought... but apparently age had taken its toll and the 5 year old coolant had started to corrode the innards of the radiator (at least I hope the rust was from the radiator). We'd never had any cooling problems with the TJ, so it wasn't until the top cap of the radiator actually started leaking that I realized there was a problem.

After I pulling the cap off the radiator, I really knew something really wasn't right...

So, time to drain the radiator...

And flush it. I used used a Prestone t-fitting flush kit, but instead of permanently mounting the t-fitting in the heater hose, I got a new section of heater hose and just plumbed in the new fitting and section of hose for the flush then took it out when I was done.

With the nastiness flushed out, pop the overflow tank off the fan shroud.

Then unbolt the fan shroud from the radiator using a 7/16" wrench and push the shroud back over the fan.

Then with the help of some socket extensions, remove the 7/16" bolts that hold the radiator to the body. Air tools are handy here, but my camera didn't want to fully cooperate on where to focus.

Disconnect the upper and lower radiator hoses and pull the radiator out. You can see where the top tank had been leaking down the right side of the radiator.

Jeepin Jason · 12-29-2005, 11:15 PM

While I was working on the cooling system, I figured I'd go ahead and change the thermostat for good measure. Good thing too, looks like some gunk was hiding up in there too.

After some cleaning and scraping, the motor was clean and the new thermostat was in place. You'll want to have a good, sharp scraper, and take care not to get debris in the motor. I like to use a little dab of RTV to hold the thermostat in place, it makes life a bit easier when you go to put the housing back on.

You'll want to make sure you've got a new thermostat housing gasket on hand, they usually run about $2 or less from most local auto parts stores. To help make sure I had no leaks, I smeared some RTV gasket maker on there too.

So here's the new 3-core radiator from CSF. One of the nice things about it is the tanks on the top and bottom are metal and fully bonded to the radiator, unlike the clamped-on plastic tanks of the stock radiator. The fittings on the bottom are used if you've got an automatic transmission.

Single-core stock radiator vs new 3-core aftermarket.

If you've got AC, you'll need to pull a plate out of the right side of the CSF radiator.

Bolt the radiator back on the body, bolt the fan shroud to the radiator, connect the hoses back to the radiator, snap the overflow bottle back onto the fan shroud, fill 'er up, and you should be ready to go.

Complete photo album at http://jeepin.net/photos/csf

JHASH · 12-30-2005, 11:27 PM

Been 'dere, done 'dat. Holy crap that's rusty!!!!!!! Is all that rust or red clay blown in through the overflow system?

Trex · 12-30-2005, 11:43 PM

Looks like its about time to replace that belt too

Jeepin Jason · 12-31-2005, 09:15 AM

I think it's mostly rust. The area we wheel at most often is covered in red iron-oxide dirt, but the cooling system would have had to suck in an awful lot of that dust to end up like that. Plus, if that was the issue or part of the issue, my XJ would have the same problem if not worse as we take it out more than the TJ, and its coolant is still perfectly green. Our TJ doesn't get driven much, and it's five and a half years old and still had the original coolant in it (under 30k on the odometer though).

PhatYJ · 12-31-2005, 09:48 AM

Hahaha, remember this Dub?

It must not be directly related to Texas soil

My Tstat and whatnot didn't look quite as bad as yours tho. Pic, but I think my rad was in a little worse shape.

I've never seen a 'radiator flush kit' like that.... makes sense. I just stuck the garden hose in the block, and in each hose for a good hour or so off and on 'till there was nothin' but clean water comin' out of everything.

Great tune up.

Jeepin Jason · 12-31-2005, 10:01 AM

I'd forgotten about that!

Yeah, the t-fitting flush kit is pretty handy and didn't cost much. Comes with a couple of different sized t-fittings to connect to one of the heater hoses, then a spout that snaps into the radiator filler neck. After you've drained all the coolant out, you put in the t-fitting, connect the hose, stick the spout on the filler neck, turn on the hose, start the engine, and turn on the heat inside. This opens up everything and gets fresh water flushing everything out under a little bit of pressure.

12-30-2005, 11:27 PM	#3
JHASH Trail Guide Join Date: Sep 2002 Location: Shady Side Penninsula, Chesapeake Bay, Maryland Posts: 3,666	Been 'dere, done 'dat. Holy crap that's rusty!!!!!!! Is all that rust or red clay blown in through the overflow system? __________________ In Memory of Gordon Davis, Photographer, WJLA TV, Washington D.C., killed 12/19/06 while covering a story. God Bless You and Keep You, Gordo. I'll miss ya, buddy. TJ on 35's

12-30-2005, 11:43 PM	#4
Trex Jeeper Join Date: Mar 2004 Location: Lewisville, Tx Posts: 89	Looks like its about time to replace that belt too __________________ Trex -- 2003 Jeep Wrangler Rubicon http://www.flickr.com/photos/jtxpics/

12-31-2005, 09:48 AM	#6
PhatYJ Admin Join Date: Aug 2002 Location: PacNW Posts: 51,419	Hahaha, remember this Dub? It must not be directly related to Texas soil My Tstat and whatnot didn't look quite as bad as yours tho. Pic, but I think my rad was in a little worse shape. I've never seen a 'radiator flush kit' like that.... makes sense. I just stuck the garden hose in the block, and in each hose for a good hour or so off and on 'till there was nothin' but clean water comin' out of everything. Great tune up. __________________ A well regulated militia being necessary to the security of a free state, the right of the people to keep and bear arms shall not be infringed.