Aftermarket Radiator doesn't fit 1990 B2

[fishbreath]

I recently purchased an aftermarket radiator (Ready-Rad part number 431327) for my 1990 Ford Bronco II (2.9 litre, Auto Trans, 2WD). After installing this radiator I could not fit the lower hose onto the outlet. The bottom tip of the lower hose outlet is about three inches lower than the original lower hose outlet location. This causes interference with the stock sway bar mount. I could have probably cut the hose short and crammed the radiator in place, but it would cause the hose to rub (or severely interfere with) the sway bar mounting bolts. At best this would cause a hose failure, but more likely it would cause the plastic tank to break, in time. So, needless to say I returned the radiator to the store. Ready-Rad part number 431327 is the correct number for this application (and many Rangers), there was no mistake there. Since then, all of the replacement radiators I have found (by looking at on-line photos) have the same lower hose outlet location.

I am well aware that many other years of Ford Ranger have the same radiator, but this does not solve the problem. The problem is that the proper radiator (which also fits those Rangers) has been changed to have a lower hose outlet that is 3" lower than the stock radiator. Aftermarket manufacturers strive to make compromises to their parts so that those parts fit many different applications. Everybody has seen this when the new part looks different than the old one, but fits and works properly. This way the manufacturer stocks fewer part variations, which saves them money. However, once in a while (as in this case) an aftermarket manufacturer makes a modification that will not work in some of the applications where it is intended to be used.

So, in this case, several aftermarket radiator manufacturers (maybe all of them) have made a modification to their radiator, by moving the lower hose outlet down three inches from the stock location, and causing an interference problem with the sway bar mount (at least on my 1990 B2 2WD Auto Trans). Of course this radiator may work fine in many of the other applications for which it is intended, or it may not. The Rangers could also start experiencing this problem if the sway bar mount is the same.
I do not want a junkyard radiator, nor do I want to make modifications (unless I absolutley have to). Additionally, I have taken the radiator to a radiator shop (owned by an old guy who is well respected) who says they don't sell cores for these radiators any more.

Has anyone else experienced this problem, and what radiator manufacturer and part number still has the lower hose outlet in the stock (higher) position?

 

[Chris88GT]

A few weeks ago I replaced my 89 B2 radiator with one from an Explorer. I ordered it through RockAuto. I got one for an automatic Explorer with A/C. This version is a 2 row radiator. It is pretty much a direct swap except for having to cut some holes in the fan shroud for the tabs to fit in. The hoses also didn't quite fit b/c the inlet/outlet on the new radiator were different. I got hoses for the same Explorer and ended up doing a little trimming on them but it fit just fine with no rubbing. However the clearance on the hoses were very tight to other parts in the engine compartment. BTW I think it was a Spectra radiator.

 

[Clem]

As you stated this is becoming a common problem with all aftermarket parts, especially radiators.
The 91-92 Explorer radiator is a little taller, which means it is dropped down further, to solve the rubbing problem on my 86 B2 before installing the 4.0. I used a new piece of exhaust pipe bend that was shortened on both ends, with a short hose piece to make the connection to the radiator. Routing the pipe upwards and toward the left of the vehicle, then into the cutoff stock radiator hose. It takes a little figuring, but ends up a sanitary job.
After installing the 4.0, the stock 92 explorer hose had to be cut and routed a little different to get it away from the steering box.
What ever you decide to do, just remember, the next time you replace the radiator or the lower hose, you will have the same problem, so do it so it works right now, then you won't have to work so hard the next time.
Paint the outside of the pipe, but not the inside, the paint chips off and gets into the heater core.

Ray