Ford Freestar, Monterey 2004-2006

Removal & Installation

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  1. Partially drain the cooling system to a level below the thermostat.
  2.  
  3. Remove the air cleaner outlet tube.
  4.  
  5. Disconnect the upper radiator hose from the thermostat housing.
  6.  
  7. Remove the thermostat housing-to-engine bolts and the thermostat housing.
    NOTE
    Mark the location of the vent pin before removing the thermostat.

  8.  
  9. Remove the thermostat.
  10.  
  11. Discard the gasket.

    Click image to see an enlarged view

    Fig. Exploded view of the upper radiator hose clamp (1), upper radiator hose (2), thermostat housing-to-engine bolts (3), thermostat housing (4), gasket (5) and thermostat (6)

  12.  

To install:

  1. Position a new gasket.
  2.  
  3. Install the thermostat. Tighten the thermostat housing-to-engine bolts in two stages:
    1. Stage 1: Tighten the thermostat housing-to-engine bolts to 71 inch lbs. (8 Nm).
    2.  
    3. Stage 2: Tighten an additional 60 degrees.
    4.  

  4.  
  5. Connect the upper radiator hose to the thermostat housing.
  6.  
  7. Install the air cleaner outlet tube.
  8.  
  9. Fill and bleed the cooling system.
  10.  

 
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