Ford Mustang GT 1996-2004: How to Replace Water Pump

This article applies to the Ford Mustang GT (1996-2004).

As a Mustang owner, you need to pay attention to the parts of your prized vehicle so that it’s constantly performing at its optimal levels. One of the more important components within the car is the water pump. This one part is tasked with pumping water and coolant to the car’s engine to ensure it never overheats. If it’s leaking, or if a bearing is loose, it can lead to the engine overheating, which, in turn, can lead to costly repairs.

A trip to the service shop to have your Mustang’s water pump replaced can cost anywhere from $300 to $500. Do it yourself and you can save a ton of money. Here’s how.

Step 1 – Let your car engine cool down

The coolant within the system is hot if the vehicle has been recently driven. Removing the system while it’s in this state can cause serious injury. Give it a few hours to cool down completely.

Step 2 – Flush the system

Get the car up and look under the radiator—there will be a drain plug. Pull and allow the system to drain.

(Related Article: How to Flush Radiator - MustangForums.com)

Step 3 – Remove water pump

You will need to remove the water pump, as well as the belts, bolts, and fan.

Remove the cooling fan motor, fan blade and fan shroud. Rotate drive belt tensioner and remove the drive belt. You’ll now have a bit more room to work with—go ahead and remove retaining bolts and water pump pulley. Remove power steering pump pulley and remove water pump-to-power steering pump brace. Remove heater water outlet tube retaining bolts and heater water outlet tube from water pump.

Disconnect the lower radiator hose from water pump. Remove the water pump's retaining bolts, stud bolts and nuts.

Remove the water pump and discard old water pump housing gasket.

(Related Article: How to Replace Serpentine Belt - MustangForums.com)

Step 4 – Install new water pump

Remember that once the new water pump has been installed, replace the belts, bolts, and fan parts.

Begin by cleaning/replacing gasket surfaces on water pump and engine front cover. Coat bolts of new water pump retaining bolt with pipe sealant and position new water pump housing gasket on water pump sealing surface. Position the pump on the engine front cover and install retaining bolts, stud bolts and nuts; make sure to tighten retaining bolts and studs to 20 to 30 Nm (15-22 lb-ft). Tighten retaining nuts to 8 to 12 Nm (71-106 lb-in).

Check out the O-ring and replace as necessary; install heater water outlet tube to water pump. Tighten retaining bolts to 8 to 12 Nm (71-106 lb-in).

Now go ahead and install lower radiator hose to water pump and tighten clamps securely. Install water pump-to-power steering pump brace and install water pump pulley. Install water pump pulley and retaining bolts. Tighten retaining bolts to 21-29 Nm (15-21 lb-ft).

Lastly, position the drive belt over pulleys and fill the engine cooling system with specified coolant mix.

Step 5 – Tighten bolts and bleed cooling system

Fill the overflow reservoir to just below the max line. Leave the overflow/radiator cap off and start the car. Let it idle for several minutes, until it gets up to operating temperature and the thermostat flips over. At that point, increase the revs a little bit to about 2,000 rpm and hold it there for about one minute. Once this is done, put the radiator cap back on and take the car for a spin and check its temperature to ensure no overheating. Overnight, place a piece of paper or cardboard underneath the engine. Come morning, check it for stains to ensure there are no leaks.

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