🔧 Fusion - Radiator Hose Replacement

Replacing a radiator hose stops coolant leaks and prevents overheating. On your Fusion, there are typically two main radiator hoses: the upper (top of radiator to engine) and lower (bottom of radiator to engine/water pump area).

Difficulty Level: Intermediate | Estimated Time: 1.0-2.5 hours

Assumption: Replacing engine-coolant radiator hose (not inverter coolant).

---

⚠️ Safety & Precautions

• ⚠️ Never open the coolant cap when hot; wait until the system is fully cool.
• ⚠️ Wear safety glasses and gloves; coolant is toxic and can burn skin.
• ⚠️ Support the car with jack stands before working underneath; never rely on a jack alone.
• ⚠️ Hybrid precaution: stay clear of any orange cables; do not disturb them.
• ⚠️ Clean spills immediately; keep coolant away from kids and pets.

---

🔧 Required Tools

You'll need the following tools for this repair:

• Safety glasses
• Nitrile gloves
• Floor jack (rated 3-ton minimum)
• Jack stands (rated 3-ton minimum)
• Wheel chocks
• Drain pan (at least 2-gallon)
• Funnel
• Trim clip removal tool
• Flat-blade screwdriver
• Hose clamp pliers (specialty)
• Pick tool
• 8mm socket
• 10mm socket
• 1/4-inch drive ratchet
• 1/4-inch drive extension
• T25 Torx bit
• Shop rags
• Work light

---

🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Upper radiator hose - Qty: 1
• Lower radiator hose - Qty: 1
• Radiator hose clamps - Qty: 2-4
• Engine coolant (Motorcraft Orange OAT 50/50 or compatible) - Qty: 1-2 gallons
• Distilled water - Qty: 1 gallon

---

📋 Before You Begin

• 🧊 Park on level ground and let the engine cool completely (at least 2-3 hours).
• 🛑 Set the parking brake and place wheel chocks behind the rear wheels.
• 🧼 Lay shop rags under the hose area; coolant will spill when the hose comes off.
• 🔑 Keep the key fob away from the car while working so it can’t power on unexpectedly.

---

🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Raise the front (for best access)

• Use wheel chocks at the rear wheels.
• Use a floor jack (rated 3-ton minimum) to lift the front jack point.
• Place the car on jack stands (rated 3-ton minimum) at the proper support points.

Step 2: Remove the lower splash shield (if equipped)

• Use a trim clip removal tool to pop out plastic clips.
• Use an 8mm socket with a 1/4-inch drive ratchet to remove small bolts.
• If Torx screws are present, remove them with a T25 Torx bit.

Step 3: Relieve pressure and prepare to drain coolant

• Place a drain pan (at least 2-gallon) under the radiator area.
• Slowly loosen the coolant cap on the reservoir using your hand; stop if you hear pressure.
• If it hisses, tighten and wait longer.

Step 4: Drain enough coolant to get below the hose level

• Keep the drain pan in place.
• If your radiator has a drain valve (petcock), open it carefully using a flat-blade screwdriver.
• If there’s no drain valve access, you can drain by loosening the lower radiator hose clamp (Step 6) and letting coolant drain into the pan.

Step 5: Identify which hose you’re replacing

• Upper radiator hose: runs from the top of the radiator to the engine area near the thermostat housing.
• Lower radiator hose: runs from the bottom of the radiator down to the engine/water pump area (best accessed from underneath).
• Do one hose at a time to avoid mix-ups.

Step 6: Release the hose clamps

• Use hose clamp pliers (specialty) to compress and slide spring clamps back. A hose clamp pliers is a locking plier tool that squeezes spring clamps and holds them open.
• If you have worm-gear clamps (screw type), loosen them with a flat-blade screwdriver.
• Position the clamp a few inches away from the hose end so it won’t interfere with removal.

Step 7: Remove the hose from the fitting

• Twist the hose by hand to break it free, then pull it off.
• If it’s stuck, use a pick tool to gently lift the hose edge and let air in (do not gouge the metal/plastic fitting).
• Catch draining coolant in the drain pan.

Step 8: Inspect and clean the fittings

• Wipe the radiator/engine fittings with shop rags.
• Make sure no old rubber is stuck to the fitting bead.
• Check for cracked plastic necks or heavy corrosion; don’t force a hose onto a damaged fitting.

Step 9: Install the new radiator hose

• Slide the clamps onto the new hose first (use hose clamp pliers (specialty) or your hands depending on clamp type).
• Push the hose fully onto the fitting until it seats against the stop/bead.
• Reposition the clamp over the fitting bead using hose clamp pliers (specialty) (spring clamp) or a flat-blade screwdriver (worm clamp).

Step 10: Reinstall the lower splash shield

• Reinstall screws/bolts using a T25 Torx bit and/or 8mm socket with a 1/4-inch drive ratchet.
• Reinstall clips using a trim clip removal tool to align them, then push them in by hand.

Step 11: Refill coolant

• Lower the car safely if you want easier filling (use the floor jack (rated 3-ton minimum) and remove jack stands (rated 3-ton minimum)).
• Use a funnel to fill the coolant reservoir with Engine coolant (Motorcraft Orange OAT 50/50 or compatible).
• If you’re mixing concentrate, use distilled water to make a 50/50 mix.

Step 12: Bleed air and verify circulation

• Start the car and set the climate control to heat (full hot) so coolant flows through the heater core.
• Let it idle and watch the coolant level; add coolant as the level drops using a funnel.
• Watch for leaks at both hose ends with a work light.
• When the engine warms up, you should feel the upper hose get hot as the thermostat opens.
• Shut off the car, let it cool, and recheck the level; top off as needed.

---

✅ After Repair

• 🔍 Inspect for leaks with the engine running and again after a full cool-down.
• 🌡️ Road test 10-15 minutes while watching the temperature gauge/overheat message.
• 🧴 Recheck coolant level the next morning (cold engine) and top off if needed.
• 🧹 Dispose of old coolant properly; do not pour it on the ground.

---

💰 DIY vs Shop Cost

Shop Cost: $250-$550 (parts + labor)

DIY Cost: $40-$140 (parts only)

You Save: $210-$410 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 1.0-2.5 hours.

---

🎯 Ready to get started?

HowToo makes it easy: same-day/2-day shipping on every part, plus all the tools and specialty tools you need! Check out the parts and tools sections below to add everything to your cart.