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I just did this yesterday. Remove the air filter assembly up to the throttle body. Remove the coolant reservoir. Unhook upper radiator hose from the fan shroud and anything else that is connected to it. There are 6 screws that attach the top part of the fan shroud to the bottom. Remove the top, leave the bottom. The rad hose and AC hose should bend enough to the towards the enging to get out the top shroud. You should probably flush the radiator now. Plug the MAF from the air filter assembly back in if you want it to run a little smoother while flushing. Watch out for the fan, and make sure it's not going to hit anything. Unfortunately your radiator probably has a non-functioning draincock, and you'll have to remove the lower radiator hose to flush and drain. Not comes the fun part. The oil cooler lines and trans cooler lines are connected to the radiator by these little c-clips. They are a pain in the rear. Use a small flat head screwdriver or something small enough to get these off. They are stainless clips, but could be surrounded by rust especially the lower ones. Try some WD40, if that doesn't work you are probably looking at new oil cooler lines (easy job). The trans cooler lines could be harder to replace, so check on that. Try to keep water from getting in the lines, and fluids from getting in your radiator hose. Unhook your upper and lower radiator hoses, and pull out the radiator. Reverse steps to install. When filling the radiator back up pour a gallon or two of coolant into the upper radiator hose and then attach to the radiator. You'll get less air in the system than if you only fill into the neck.

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Q: How do you replace the radiator on a 2003 3500 express van?
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