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Aluminum Radiator Upgrade

Aluminum Radiator Upgrade


  • (1) Howe Aluminum Radiator Summit Part number HRE-342A28 ($206.95)
  • (1) 22lb radiator cap Summit Part number HRE-3427 ($9.39)
  • (4) Complete Set of James Duff Radiator Brackets – Part Number 3105 ($35.00)
  • (1) Lower Radiator Hose – Carquest Part Number 21034 ($10.00)
  • (1) Plasma Cutter/cutting Wheel/Gas Cutting Torch
  • (2) Extra Hose Clamps for Lower Radiator Hose ($3.00)
  • (2) 3” Galvanized nipples which ½” bolt will fit through (Ace Hardware) ($3.00)
  • (2) 4”x1/2” (or 7/16”) Grade 5 Bolts with nuts, washers & Lock Washers ($4.00)
  • (1) Piece of flat steel +/- 8” long by 1-1/2” wide by ¼” ($Free)
  • (1) Drill with assorted bit sizes
  • (1) Roll of foam tape used for camper/topper shells on pickups ($5.00)


  1. Drain existing radiator. Disconnect battery & remove while draining radiator.
  2. Remove battery tray.
  3. Loosen & remove upper radiator hose from radiator. Completely remove lower radiator hose.
  4. Loosen fan shroud bolts and position fan shroud around engine fan laying on engine.
  5. Loosen both stock upper radiator mounts & remove
  6. Carefully lift stock radiator out. After radiator is out, slide shroud forward on fan & remove same.
  7. Remove lower radiator mounts & replace with Duffs. I also re-used the stock rubber isolators vs the new poly ones – it’s up to you.
  8. Remove Howe radiator from box. Cut box up to make two cardboard cut outs that will completely cover the radiator fins – one in front one in back. Zip tie the cardboard pieces to the radiator. This will protect the fins (front & back) from the numerous times you lift radiator in & out of bronco for test fitting.
  9. Place some foam tape on the drivers side of the radiator where the steering box is & carefully set Howe radiator in place. Mark area on passenger inner fender and grill core support that needs to be cut/trimmed to make clearance for lower radiator hose.
  10. Pull radiator out. Cut out passenger inner fender and grill support as marked. Trial fit radiator until you are satisfied with the clearance.
  11. Install lower radiator hose to engine. Trial fit radiator to verify lower hose clearance. Otherwise, cut more inner fender out.
  12. Take flat steel and set where battery tray went. Mark holes & drill out same. Bolt flat steel to body using the stock battery tray fastners.
  13. Use galvanized pipe nipples as spacers and turn battery tray 90 degrees. Battery tray must be trimmed +/- 3” off one end. Drill holes in metal flat strap for bolts that will run through the battery tray, through the nipples & finally through the metal strap. Mock everything up & check for clearance with hood. The galvanized nipples may need to be trimmed. I also found a Dry Cell battery (Optima) is smaller & fit better. Solenoid may need to be moved, although I kept mine in the stock location.
  14. Pull everything out. Re-check radiator for fit. Re-check battery tray for hood clearance/fit. Pull radiator out and place foam tape anywhere where clearance is tight.
  15. Install battery tray & battery. I re-used the stock battery tiedowns. Verify hood clearance again.
  16. Place shroud in engine compartment loosely around fan.
  17. Take cardboard protectors off of radiator. Place some foam tape on the lower radiator mounts & set radiator in place. Put upper radiator mounts on & tighten down – use foam tape as needed to make fit tighter.
  18. Re-attach stock upper radiator hose. Attach lower radiator hose using double clamps on radiator side.
  19. Attach shroud to radiator, carefully drilling holes as needed. (I didn’t have to drill any holes in my install – it lined up perfectly with existing holes).
  20. Jack up front end to help remove air pockets & fill radiator.
  21. Start engine & top off as necessary.
  22. Install 22 – 24lb cap.

Enjoy thoroughly – my bronco ran consistently 25 degrees cooler all the time vs my custom POS 5 core brass radiator.

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