Radiator Barn Radiators
Here's a pic of the new 3-core all metal replacement radiator
It is very common for a TJ radiator to leak where the top is clamped on
Drain your radiator into a bucket
Remove the hose connecting your radiator to the overflow bottle
Remove the radiator overflow bottle by pushing on the round tab in the middle and pulling upwards
Using an 11mm wrench or socket, remove the 4 bolts attaching your fan shroud to your radiator
Set your loose fan shroud back on the fan blades
Using hose clamp pliers or channel locks, remove the upper hose from your radiator
Again, using hose clamp pliers or channel locks, remove the lower hose from your radiator
Using a 10mm wrench or socket, remove the 6 bolts attaching your differential breather hose and radiator to your grill
Carefully slide your new CSF Metal Radiator into place being extra careful not to damage any of the fins
Attach your new CSF radiator to your grill using the 6 factory bolts you removed previously
Attach your lower hose onto your new CSF radiator. The 2 smaller brass nipples on the base of the radiator is for an automatic transmission cooler. These do not need to be plugged
Attach your upper hose to your new CSF radiator
Fill up your new CSF radiator and overflow bottle using a 50/50 mix of coolant/anti-freeze
Heavy Duty All Metal 3-Core Radiator

If you own a Jeep TJ and don't already have a factory radiator that's leaking, believe me it's only a matter of time until it does. I consider myself lucky to have gotten about 85,000 miles out of mine, but I know of guys who's radiators went bust at only 25,000 miles. In every case, the failure occurs where the plastic top is clamped onto the main body of the radiator. Over time, this seal works itself loose and then leaks like a sieve. To top it off, because of this stupid plastic/metal design Jeep decided to use, the leak cannot be repaired and a replacement will be needed.

Fortunately for us, a brand new all metal heavy duty 3 core replacement radiator can be had from Radiator Barn for only $155 shipped to your door. This of course is a direct fit replacement, comes with a FREE lifetime warranty and comes equipped to work on manual and automatic transmissions. Installation is easy and can be done in about an hour following this simple write-up.

What You Need
• CSF Heavy Duty All Metal 3 Core Radiator
• 1 - Gallon Coolant/Anti-Freeze or 2 - Gallons 50/50 Pre-Mix
• 1 - Gallon Distilled Water
• 10mm, 11mm, 1/16" Sockets
• Ratchet
• 3" Ratchet Extension

• Hose Clamp Pliers or Channel Locks
• 2 - 1-3/4" Stainless Steel Hose Clamps
• Large Bucket
• Rags
• 2 - 1 Gallon Milk Jug

1. Park your Jeep on a level surface, pop open your hood and let your engine cool before proceeding with this install.

Carefully inspect your upper and lower radiator hoses for any signs of crack or damage. If any is found, go to your auto parts store and pick up replacements before continuing.

3. Place a large bucket underneath your radiator drain valve which is located on the passenger side of your Jeep. Open the drain
valve by twisting the knob by hand. Because you will not be needing this radiator anymore, open the fill cap to allow the coolant/anti-freeze to flow more rapidly.

4. While your coolant/anti-freeze is draining, remove the rubber hose attaching your overflow bottle to the neck of your radiators fill cap.

5. Remove your Jeep's overflow bottle from your radiators fan shroud by pushing on the round tab midway down the bottle and pulling straight up. Place the bottle upright somewhere it won't get knocked down.

6. Using an 11mm socket or wrench, remove the 4 bolts that attach your fan shroud to the radiator. Start with the bottom ones first and then the top. Set your loose fan shroud back on the fan blades and out of the way.

7. Now, using a pair of hose clamp pliers or large channel locks, remove your upper hose from your radiator.

8. Again, using hose clamp pliers or channel locks, remove the lower hose from your radiator. Some coolant/anti-freeze will most likely leak out here so be sure to have a rag handy and keep your face out of the drip zone. (NOTE: If you have an automatic, remove the 2 hoses going to the automatic cooler at this time)

9. Using a 10mm socket or wrench, proceed to remove the lower and middle bolts attaching your radiator to the grill. If you are using a ratchet, a 3" extension really comes in handy here. Remove the upper 2 bolts and differential breather hose last. Remove your old radiator from your engine compartment.

10. If you haven't already done so, remove your new CSF radiator from it's box and then carefully slide it into place being extra careful not to damage any of the fins by bumping into something.

11. Attach your differential breather hose as well as the upper 2 radiator bolt to your grill. Then, proceed to attach the other 4 bolts securing your new radiator in place.

12. Climb under your Jeep and attach the lower hose to your new radiator. I don't like the factory hose clamps so I replace mine with standard stainless steel 1-3/4" screw on clamps. A 5/16" socket will make the task of fastening your clamp much easier.

NOTE: If your hose was in need of replacing, do it at this time.

13. Now, get back up under your hood and attach the upper hose to your new CSF radiator just like you did on the lower hose. Again, I recommend replacing your factory hose clamps with a standard stainless steel screw on type.

14. Re-attach your fan shroud to your new CSF radiator using the 4 factory bolts you removed earlier

15. Slide your radiator overflow bottle back onto the fan shroud and make sure it snaps into place. Attach the rubber overflow bottle hose to the neck of the radiator fill cap.

16. Fill your radiator up with a 50/50 mix of coolant/anti-freeze. If you are doing your own mixing, make sure to use distilled water. Once your radiator is full, make sure to fill your overflow bottle to the "Full" mark and cap both.

17 - Automatic Transmission Only: Hook up your transmission cooler hoses to the two nipples located on the base of your new CSF radiator.

18. Start your engine and let it warm up to operating temperature (210° F). Check for leaks and make adjustments as needed. Turn off your engine, let it cool again and add more coolant/anti-freeze to your overflow bottle as needed.

19. Pour your coolant/anti-freeze into 1-gallon milk jugs and take them into your local auto parts store for recycling.

That should be it. Your Jeep now has a good solid all metal radiator that should last a long, long time. Please let me know if you have any other questions.

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