Flex-a-Lite 52100 Mustang Radiator Fits 1979-1993 Mustang 5.0L - Manual (Page 2)

Installation of Radiator and Fan Combo
#52185 or Radiator only #52100
1. Find the new radiator overflow bottle
and mounting bracket. Mount the bracket
(#51107) to the radiator on the filler side as
shown in detail 7. Now mount the overflow
tank to the bracket with the fasteners
provided with the overflow bottle as shown
in detail 8. Note: DO NOT allow the filler
cap of the overflow bottle to exceed the
height of the top of the radiator for clear-
ance (see detail 7 and 8).
2. Attach the hose to the “short” tube on the
bottom of the overflow tank. Use a hose
clamp to hold it in place. DO NOT connect
the hose to the radiator yet. Note: The
longer tube on the bottom of the overflow
tank is a breather tube, DO NOT obstruct
or remove it.
3. Mount the large lower bracket (#51105)
to the lower edge of the core support with
the four (4) bolts, four (4) washers and four
(4) lock nuts. DO NOT secure the bracket completely. There should be enough
movement for adjustment to the bracket later (see detail 9).
4. Flare or bend the lower orginal radiator mounts towards the engine slightly to
make enough room for the new radiator to rest in the lower mounts. This may
require the use of pliers. DO NOT remove the rubber in the mount, it will provide
a cushion for the new radiator.
5. Lower the radiator into the vehicle. Be sure that there is enough clearance
between the overflow bottle and the battery. Place the radiator as far forward, or away from the engine, as possible to
allow enough clearance between the fan and the water pump. Note: Every vehicle may vary, some adjustments may need
to be made for a better fit.
6. Using two (2) each of t-studs and nuts, fasten the lower bracket to the bottom of the radiator. Push the radiator toward
the front of the car, away from the engine. Tighten all of the fastners on the lower bracket (see detail 10).
7. Install the two (2) upper brackets (#51104) with the original bolts from the original top brackets. Using 2ea. t-studs
and locknuts, fasten the brackets to the top of the radiator utilizing the channels in the radiator side tank. Pull the radiator
toward you (away from the engine) as you tighten the fasteners for maximum clearance between the fan and the engine
(see detail 11).
8. Install the pipe-nipple for the overflow tube to the filler neck of the radiator. Route and trim the overflow hose as
needed. Note: Be sure that there is enough clearance of the hose to any moving engine components.
9. Connect the upper and lower radiator hoses to the radiator. Make sure they are properly clamped to the inlet and outlet
tubes. Note: BE SURE that all moving parts of the engine and electric fan are clear of each other before proceeding!!
Detail 7
Detail 8
Detail 10
Detail 11
10. Remove the upper and lower hoses of the radiator. It is not necessary to remove them completely from the vehicle
for installation. (see detail 5 on page 1).
11. Using a 1/2” socket or wrench, remove the two (2) brackets that hold the original radiator in place at the top. Note:
Save these bolts to be used later. (see detail 6 on page 1)
12. Remove the original radiator by lifting it straight up. Note: Use caution while removing the radiator, it may still
contain coolant which can spill out.
Removal of the original radiator and fan cont’d.
rev. 02-26-09 #54993 Page 2 of 4
Detail 9