Radiator Tank Replacement
Radiator Core Header Tabs:
TANK REMOVAL
NOTE: The radiator tanks are molded, glass-filled nylon and are attached to the core header by bending the header tabs over the edge of the tank. When removing a nylon tank, a screwdriver or one of the various special tools available can be used to open the header tabs. Some of these tools, including a screwdriver, may cause a small section of the header side to bend with the tabs as they are opened. This slight deformation is permissible, provided the tabs are opened only enough to tank removal. The header sides will usually return to the normal position when the tabs are crimped during tank installation. Procedures are given for tank removal using a screwdriver of a Borroughs Tool BT-8260. Follow the manufacturers instructions for other radiator tab opening and closing tools.
Lifting Tabs With Screwdriver:
WITH SCREWDRIVER
1. Insert the end of a medium tip screwdriver between the end of the header tab and the tank. Then, press the screwdriver blade against the tank to bend (pry) the tab away from the tank edge. Repeat this procedure for each tab.
NOTE: Bend (open) the tabs only enough for tank removal.
2. Lift the tank from the core header when all of the header tabs are bent away from the tank edge.
3. Remove the O-ring gasket from the header.
Lifting Header Tabs With Borroughs Tool:
WITH BORROUGHS TOOL BT-826O
1. Insert the end of Borroughs Tool BT-8260 between the end of the header tab and the tank. Then, push the tool handle down toward the core to bend the tab away from the radiator tank. Do not open the tabs more than is necessary for tank removal.
2. Repeat Step 1 for each header tab. Then, lift the tank from the header.
3. Remove the O-ring gasket from the header.
Proper O-Ring Alignment:
INSTALLATION
NOTE: If any header tabs are missing from an aluminum core, the core should be replaced.
1. Inspect the seal surface of the radiator core header to ensure it is clean and free of foreign material or damage.
2. Check the new O-ring to ensure it is not twisted.
Exploded View Of Crossflow Radiator Assembly:
3. Dip the new O-ring gasket in glycol or silicone or equivalent lubricant, and place the gasket in the header groove.
4. If the outlet tank is being replaced and is equipped with an oil cooler transfer the oil cooler from the replaced tank to the new tank as outlined.
Holding Tank To Header With Barbee Crimp Clamps:
5. Position the tank to the header using care not to scratch the tank sealing surfaces with the header tabs. Be sure the top and bottom of the tank is position properly with the other tank.
6. Clamp the tank in position on the header with two header clamps as shown. Tighten the header clamps to compress the O-ring gasket.
Setting Proper Crimping Diameter:
7. If locking-type pliers are used to squeeze the header tabs against the tank, install a hex nut on the pliers adjusting screw.
8. With the jaws of the locking-type pliers closed and locked, turn the adjusting screw to position the jaws against the shank of a 13/32 inch drill bit. Then, tighten the hex nut on the adjusting screw against the handle to lock the adjustment in place.
Using 13/32 Diameter Locking Plier On Header Tabs:
9. Squeeze the header tabs down against the lip of the tank base with the locking-type pliers while rotating the pliers toward the tank.
Crimping Header Tabs With Borroughs Tool:
10. If a special crimping tool is used follow the manufacturer's instructions.
Proper Height (10.3 mm) (13/32 inch) Of Crimped Header Tabs:
NOTE: It is important that the assembled height of the crimp be 10.3 mm (13/32 inch) when measured from the bottom of the header to the top of the tab.
11. Remove the header clamps and squeeze the header tabs down that were behind the clamps.
12. Leak test the radiator at 145 kPa (21 psi). Most minor leaks at the header-to-tank seal can be corrected by again squeezing the header tabs down against the tank lip in the area of the indicated leak.