Explorer Serpentine Radiator Retrofit

Installing my explorer serpentine, I have been looking for an inexpensive solution to the radiator and radiator hose issue. I did not really like the idea of buying a custom radiator because of the cost. I also was not very excited about the crossover hose option because I want to be able to use off the shelf hoses. Researching, I read two posts about using a V6 explorer radiator but found no real tech info. So, after a couple trips to the junk yard and alot of measuring, I think I have figured it out and it appears that it will work well. The radiator is from a 4.0 liter 94 Explorer. It is very similar to the Bronco radiator in size but mounts a bit different. The explorer radiator has pegs on the bottom that fit into rubber grommets. When I got the radiator, I grabbed the grommets as well. After removing the stock radiator and hold down brackets, I test fit the radiator. For the lower mounts, I cut a piece of 2" flat bar the width of the new radiator and cut holes in it for the grommets. Next, I test fit again and marked the bar where the original bolt holes are for the original lower radiator brackets. The bolt holes fall very close to the rubber grommets so I cut some 3/4" square tube and welded it to the bottom of the flat bar and welded nuts into it. Now I can just bolt the bar down to the original mounting holes for the stock radiator. For the upper mounts, I wanted to use the mounting holes that the radiator has but they fall slightly higher than the radiator core support. I solved this with a couple more small pieces of flat bar. I just drilled a couple holes in the bar and the core support I then bolted the the short pieces of flat bar to the core support and the radiator to the bar. The top of the radiator is very close in height to the original radiator and the hood closes fine. Here are a few photos I took and I'll post more of it installed after I have it installed again. I took it back apart for now so that I could paint the flat bar pieces.

In the photos you can see:
The two radiators side by side
The peg mounts for the bottom of the radiator and grommets ( Radiator is upside down )
A couple test fit photos
The new lower radiator mounts with the grommets in it

I only paid $37 for the radiator and I should be able to use stock explorer radiator hoses.

Very nice. Any pics with the hoses hooked up to the engine?

Not yet, but I'll post more when I get there.

Well the explorer radiator works like a champ! I got it all installed and tested it this evening. I took some more photos but have not downloaded and resized them yet. As soon as I get them done I'll get it posted. The only thing left to do is figure out a fan shroud. I have been running without one for several years with no problems but its time to do this right. I have a stock shroud that is a good fit for the explorer fan but I have a body lift of 2 1/2" so I will need to modify it or come up with another plan.

Here is what the Explorer radiator install looks like. The best thing about it is that I was able to use 5.0L explorer radiator hoses. I had to cut a little off of each end of the lower radiator hose but it fits very well, especially when you consider they are for a 99 explorer 5.0l and the radiator is from a 94 explorer 4.0l. On the upper hose, I used the explorer water neck instead of the Bronco neck to make the hose fit better. The Bronco neck comes out of the intake at about a 45 degree angle where the explorer neck comes out of the intake at a 90 degree angle.

Very nice mod, let us know how well it does cooling when you get it on the road.

Did you try the 4.0L explorer shroud?
I have one on my 5.0L conversion and it works OK, should be an good fit with your radiator.

VERY NICE! I have a feeling that my old stock radiator in the bruggy is going to need replaced soon. I had considered trying this just for ease of hoses and having an off-the-shelf radiator to buy when in a jamb. Thanks for the info and pictures!

Tito said:

Very nice mod, let us know how well it does cooling when you get it on the road.

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Thanks, I actually drove it for about 45 minutes last night then let it idle in the driveway for another 30 minutes and it never got above 185. The real test will be 100 degree weather next summer but I pretty confident it will be good. I'm pretty sure that this radiator holds more fluid than stock radiator does so that has to help a little bit.

I did not try the 4.0l shroud but the stock Bronco shroud looks like it will be a good fit. It will just need to be mounted down on the radiator a little lower than stock due to my body lift.

This looks promising. I might have to take this route as well.

I saw you can get a brand new one of these on eBay for around $75 shipped to your door, and $125 for an all aluminum one.

That alone is cheaper than just buying the hose kit from BC.

Thanks for sharing the info!!

Accordngs said:

This looks promising. I might have to take this route as well.

I saw you can get a brand new one of these on eBay for around $75 shipped to your door, and $125 for an all aluminum one.

That alone is cheaper than just buying the hose kit from BC.

Thanks for sharing the info!!

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I got mine in the junkyard for $37 but I'm pretty sure its almost new. At least it looks new so I'm thinking it was replaced shortly before getting sent to the yard. When I was looking, I found several some were copper and some aluminum. I grabbed the aluminum one because of its like new condition but I would have been just as happy with one that was not aluminum. They all have plastic tanks. If you decide to order a radiator or if you are junkyard diving, be sure you get the correct radiator because there are two versions. I found several that were 1" single row radiators, Look for the 2" 2 row. I believe most explorers with Air Conditioning have the larger radiator.

I'm gonna go drive it some more.

has anyone tried an explorer 5.0l radiator?

5.0 explorer radiator is to wide and tall to fit in the bronco, I had one and it did not work.

OK, darn, I'm just thinking that those pesky engineers do tend to make things that work, so if your using a 4.0l radiator with your 5.0l motor, it might tend to get a bit warm, especially if you hop up the motor a little.

was the 5.0 radiator to thick as well? That might be a way around any cooling issues, make it thicker.

73azbronco said:

OK, darn, I'm just thinking that those pesky engineers do tend to make things that work, so if your using a 4.0l radiator with your 5.0l motor, it might tend to get a bit warm, especially if you hop up the motor a little.

was the 5.0 radiator to thick as well? That might be a way around any cooling issues, make it thicker.

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behemoth is correct, the 5.0l radiator is too wide and tall as is the later model 4.0l. The 94 Explorer is the older more square body style so apparently the radiator was part of the design change when they changed the body. As far as I know, there was not a 5.0 explorer in the early body style. As for the radiator not being large enough, I don't believe it will be a problem. If you look at the top of the thread you can see the stock radiator is very close to the same size as the explorer radiator that I used and it also appears to hold MORE coolant than my stock radiator did. I have never had cooling issues and I'm running a 69 351w bored 30 over so if its keeping that cool without a fan shroud it will probably be OK. It may be different if you're already having cooling problems or if you live in a very hot climate. Another thing I thought about is that my stock radiator is in very bad condition and has a ton of the tubes pinched off plus its 35 years old. In my case, almost any radiator I stuck in there was going to be an improvement;D . My experience with cooling problems is that no 2 engines are the same. My brother and I were having cooling problems with a 351w in a 67 mustang. We swapped in a different 351w bored 20 over and had no problems with cooling using the same radiator....go figure. I've been luck and had no cooling issues to date with my motor even with my old ass clogged up soldered together stock radiator. (Knocking on wood here )

casadejohnson said:

I got mine in the junkyard for $37 but I'm pretty sure its almost new. At least it looks new so I'm thinking it was replaced shortly before getting sent to the yard. When I was looking, I found several some were copper and some aluminum. I grabbed the aluminum one because of its like new condition but I would have been just as happy with one that was not aluminum. They all have plastic tanks. If you decide to order a radiator or if you are junkyard diving, be sure you get the correct radiator because there are two versions. I found several that were 1" single row radiators, Look for the 2" 2 row. I believe most explorers with Air Conditioning have the larger radiator.

I'm gonna go drive it some more.

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Good point! I noticed some online had the option of with air conditioning. This is definitely a route I think I will be taking. Cheaper than getting the mandrel bent pipe kit....and my fabricating skills aren't good enough to swap around inlets/outlets.

The only bone I have with you is where in the HELL was this a week ago! I embarked on the endeavor of switching my inlet/ outlets on my WH staggered 4 core to get it to work and what a PITA! I would have done this mod in a heartbeat! Keep us posted on how it cools and I may do it anyway (depending if my brazing job leaks like a sieve) and for the ease of hose changes as mine are custom with some rubber ends and exhaust tubing...

Awesome mod!

Fungus

Nice find. I'm also interested in the long term test results.

fungus said:

The only bone I have with you is where in the HELL was this a week ago! I embarked on the endeavor of switching my inlet/ outlets on my WH staggered 4 core to get it to work and what a PITA! I would have done this mod in a heartbeat! Keep us posted on how it cools and I may do it anyway (depending if my brazing job leaks like a sieve) and for the ease of hose changes as mine are custom with some rubber ends and exhaust tubing...

Awesome mod!

Fungus

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Thats pretty funny! I had a passing thought about switching the inlet and outlet then I remembered how bad the original radiator was. The sad part is it would have been done a week ago had I purchased the correct radiator the first time. I had purchased a 99 radiator by mistake because I started researching this a while back and when I was at the junkyard, I misread my 94 for a 99 in my notes. I was able to go back and trade the radiator out for the correct one on Wednesday but did not get a chance to finish the install till this weekend.

I'll keep you updated on how it cools.

Viperwolf1 said:

Nice find. I'm also interested in the long term test results.

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So far the only test has been in town diving at 60 degrees. I don't imagine we will be seeing 90 degrees outside for a while so that test won't come till next summer but I think another big advantage is the explorer fan. Previously, I was using a generic flex fan. The explorer fan is a 9 blade fan and I believe it moves quite a bit more air than my previous fan. I say this not because I have any idea what the Cubic Feet Per Minute of Air moved is but because I could feel more air movement when I was checking for leaks after the install. Not very scientific but I'm confident that its moving more air. I guess Summer time will be the real test!