Cooling System - Excessive Coolant Overflow
90ford40 Article No. 90-25-15COOLING SYSTEM - 3.0L & 4.0L - EXCESSIVE RADIATOR COOLANT OVERFLOW FROM OVERFLOW BOTTLE
LIGHT TRUCK: 1989-90 AEROSTAR
This TSB article is being republished in its entirety to correct the part number for the Cap/Hose Assembly (F19Z-8K103-A).
ISSUE: Excessive radiator coolant overflow from the overflow bottle may occur. This usually happens when the ambient temperature is high and when the engine is operating under extreme conditions such as maximum trailer towing while driving up a maximum grade hill. The coolant could overflow if the truck is immediately shut off. This is caused by an overflow bottle that is too small.
ACTION: Install a new larger volume overflow bottle and hardware to prevent excessive coolant overflow. Refer to the following procedure for service details.
1. Disconnect both the negative and positive battery cables. Remove the battery hold-down assembly and battery.
Figure 1:
2. Remove the four (4) battery tray retainer screws, Figure 1.
a. Lift the battery tray out of the engine compartment.
b. Remove the negative battery cable retainer which is fastened to the tray.
c. Attach the negative battery cable retainer to the new battery tray (F19Z-10732-B).
3. Remove the overflow bottle filler neck retainer screw at the radiator support, Figure 1.
4. Remove the overflow bottle retainer screw at the inner fender well.
5. Disconnect the overflow hose at the radiator cap nipple.
6. Disconnect the windshield washer supply hose above the plastic filter.
CAUTION: USE CARE NOT TO DAMAGE THE FILTER.
7. Pull the overflow bottle up and out of the engine compartment. Disconnect the windshield washer pump and low fluid level sensor connectors.
NOTE: THE LOW FLUID LEVEL SENSOR IS NOW DEACTIVATED.
8. Remove the washer supply hose from the overflow bottle.
9. Replace the windshield washer pump connector.
a. Cut the old connector off the wiring harness.
b. Splice in the new jumper harness.
c. Check for proper orientation. The new harness is color coded the same as the original.
10. Connect the washer supply hose to the new overflow bottle.
11. Connect the windshield washer pump connector.
12. Position the new overflow bottle in the engine compartment.
13. Connect the washer supply hose and filter to the washer fluid line.
14. Install the overflow bottle retainer screws at the inner fender well.
15. Install the overflow bottle filler neck retainer screws at the radiator support.
16. Fill the overflow bottle to the "COLD FILL" mark with 50/50 antifreeze and water.
17. Install the cap/hose assembly at the overflow bottle and at the radiator cap nipple.
18. Position the new battery tray in place and install the retainer screws.
19. Position the battery on the tray. Install the battery hold-down assembly.
20. Connect the battery positive and negative cables. Be sure to position the negative cable in the retainer attached to the tray.
21. Refill the washer bottle.
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: Eligible Under Basic Warranty Coverage
OPERATION DESCRIPTION TIME
902515A Install Overflow Bottle 0.4 Hr.
DEALER CODING
BASIC PART NO. CONDITION CODE
17618 11
OASIS CODES: 402000