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How To Replace Radiator Coolant Overflow Bottle 04-08 Ford F150

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  1. step : Removing the Coolant Bottle (0:39)
    • Loosen the upper coolant bottle hose clamp with pliers
    • Pull the hose off the coolant bottle
    • Remove the two 8mm bolts from the coolant bottle
    • Clamp the lower coolant bottle hose clamp with vise grip pliers
    • Have a drain pan ready
    • Loosen the lower coolant bottle hose clamp with pliers
    • Pull the hose off the coolant bottle
    • Release the relay box tabs
    • Pull back the relay box
    • Pull the coolant bottle up and out
  2. step : Installing the Coolant Bottle (2:03)
    • Lower the coolant bottle into place
    • Clip the relay box into place
    • Insert the two 8mm bolts into the coolant bottle
    • Loosen the lower hose clamp with a flat blade screwdriver if necessary
    • Push the lower hose onto the coolant bottle
    • Tighten the hose clamp with pliers
    • Push the upper hose onto the coolant bottle
    • Tighten the hose clamp with pliers
  3. step : Filling the Coolant Bottle (3:46)
    • Twist off the coolant bottle cap
    • Add coolant to a level between the cold fill lines
    • Twist on the coolant bottle cap
    • Periodically check the coolant level
    • Add coolant as necessary

Brought to you by 1AAuto.com, your source for quality replacement parts and the best service on the Internet.

Hi, I'm Mike from 1A Auto. I hope this how-to video helps you out, and next time you need parts for your vehicle, think of 1AAuto.com. Thanks.

In this video, we're going to show you how to replace the radiator overflow bottle on this 2005 Ford F150. It's the same part and similar process on these F150s from 2005 to 2008. The items you'll need for this are a new radiator overflow bottle from 1AAuto.com, an 8 millimeter socket and ratchet, a pair of pliers, a pair of locking pliers, a drip pan, and a flat blade screwdriver.

Using a pair of pliers, just push the ends together on this hose clamp and slide it down the hose. Then pull the hose free. Then remove these two 8 millimeter bolts. We'll just fast forward as Mike does that. Here I take a pair of locking pliers and pinch off the hose. That's basically just because our bottle is still in good shape. If you're replacing your bottle, most likely it's because it's cracked and there's not going to be any fluid in there anyway.

Now take a large pair of pliers and squeeze that clip. Usually you can get that clip to unstick from the hose and slide it down, but ours was a little difficult so I ended up squeezing the clip and just pulling the hose off at the same time. You'll see some water come out, but again, if yours is cracked, most of you won't have any water in there. Now push the tabs on either side of this box and slide it out of the way. Then lift your radiator overflow bottle up and out.

On the left, is the old radiator overflow bottle. On the right, is the new one from 1A Auto. You can see they're identical and will fit exactly the same. Reinstall your bottle. You can see we are reinstalling the old one because it is still in good, working order. Put it in place and then push that relay box back in place. Make sure your bottle's lined up and then replace those two 8 millimeter bolts and tighten them up.

If your clamp is stuck on your hose, you can just push the tabs on it and then use a flat blade screwdriver to separate the hose from the clamp. We're just trying to break it free. Now take the larger hose, push it back onto your radiator overflow bottle, and then slide that large hose clamp back up. Slide this hose into place and then, using your pliers, slide the hose clamp back into place. If the clamp stays clamped together, just tap it a couple times and it'll open up.

Now remove the cap to your overflow bottle and, if you're going to use a funnel, make sure it's a clean funnel. Then just pour in your coolant. Fill it to between the cold fill lines. Put the cap back on, and then just check it before you drive it each time the first few times you drive it.

We hope this video helps you out. Brought to you by www.1AAuto.com, your source for quality replacement parts and the best service on the Internet. Please feel free to call us toll-free, 888-844-3393. We're the company that's here for you on the Internet and in person.

Tools needed for replacement:

    General Tools

  • Drain Pan

  • Pliers, Cutters & misc Wrenches

  • Slip-Joint Pliers
  • Needle nose pliers
  • Vise Grip Pliers

  • Ratchets & Related

  • Ratchet

  • Screwdrivers & Related

  • Flat Blade Screwdriver

  • Sockets - Metric

  • 8mm Socket

2003 - 2006  Ford  Expedition
2004 - 2004  Ford  F150 Truck
2005 - 2008  Ford  F150 Truck
2006 - 2008  Lincoln  Mark LT
2003 - 2006  Lincoln  Navigator

03-06 Expedition, Navigator; 04-08 F150 New body; 06-08 Lincoln LT Radiator Overflow Tank w/Cap

Ford Lincoln Coolant Reservoir Dorman 603-028

This part replaces:

  • Dorman 603-028
  • OE # 5L3Z8A080AA
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