Dodge Ram Truck 1500-2500-3500. Manual — part 243

3. Remove the hose clamps and hoses from radiator.

4. Remove the coolant reserve/overflow tank hose

from the radiator filler neck.

5. Remove the coolant reserve/overflow tank from the

fan shroud (pull straight up). The tank slips into
slots on the fan shroud.

6. Unclip the power steering hoses from the fan

shroud.

7. Disconnect the electrical connectors at the wind-

shield washer reservoir tank and remove the tank.

8. Remove the fan shroud mounting bolts and pull up

and out of the radiator tank clips. Position shroud
rearward over the fan blades towards engine.

9. Disconnect the transmission cooler lines from the

transmission cooler, then plug the transmission
lines and cooler to prevent leakage.

10. Disconnect the power steering lines from the

power steering cooler, then plug the power steer-
ing lines and cooler to prevent leakage.

11. Remove the two radiator upper mounting bolts.

12. Lift the radiator straight up and out of the engine compartment. Take care not to damage cooling fins or tubes

on the radiator and oil coolers when removing.

NOTE: The radiator is equipped with one alignment dowel on the bottom of the outlet tank and one retain-
ing bracket on the front side of the inlet tank. Both features have rubber insulators attached to them that
must be present. The alignment dowel fits into a hole at the bottom of the front end sheet metal vertical
support post and the support bracket rests on top of the lower radiator closure tube.

5.9L DIESEL ENGINE

1. Disconnect both battery negative cables.

WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIA-
TOR DRAINCOCK WITH THE SYSTEM HOT AND
UNDER

PRESSURE.

SERIOUS

BURNS

FROM

COOLANT CAN OCCUR.

2. Drain the cooling system (Refer to 7 - COOLING -

STANDARD PROCEDURE).

WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUM-
BER 6094). ALWAYS WEAR SAFETY GLASSES
WHEN SERVICING CONSTANT TENSION CLAMPS.

CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only an original equipment
clamp with a matching number or letter.

3. Remove air box and turbocharger inlet tube.

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ENGINE

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4. Remove coolant tank hose, washer bottle hose and the positive battery cable from the fastening clips located on

top of the radiator.

5. Remove hose clamps and hoses from radiator.

6. Remove fan shroud mounting nuts from mounting brackets.

7. Pull shroud toward front of vehicle to clear mounting brackets

8. Turn shroud slightly and push toward engine to gain clearance for radiator.

9. Remove the power steering cooler mounting bolts and position the power steering cooler out of the way.

10. Disconnect the transmission cooler lines at the transmission cooler. The transmission cooler will remain on the

radiator and can be removed as an assembly.

11. Remove the two radiator upper mounting bolts.

12. Tilt radiator toward front of vehicle and lift out of engine compartment. The bottom of the radiator is equipped

with two alignment dowels that fit into holes in the lower radiator support panel. Rubber biscuits (insulators) are
installed to these dowels. Take care not to damage cooling fins or tubes on the radiator and air conditioning
condenser or the electronic viscous fan connector when removing.

8.3L ENGINE

WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP. ALWAYS WEAR SAFETY GLASSES WHEN
SERVICING CONSTANT TENSION CLAMPS.

1. Disconnect both battery negative cables.

2. Drain the cooling system (Refer to 7 - COOLING -

STANDARD PROCEDURE).

3. Remove radiator fan (Refer to 7 - COOLING/EN-

GINE/RADIATOR FAN - REMOVAL).

4. Remove the power steering cooler mounting bolts

(1) and pushpins (5). Position the power steering
cooler out of the way.

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ENGINE

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5. Lower vehicle.

6. Remove the two radiator upper mounting bolts.

7. Lift radiator straight up and out of engine compart-

ment. The bottom of the radiator is equipped with
two alignment dowels that fit into holes in the lower
radiator support panel. Rubber biscuits (insulators)
are installed to these dowels. Take care not to
damage cooling fins or tubes on the radiator and
air conditioning condenser when removing.

CLEANING

Clean radiator fins are necessary for good heat transfer. The radiator and oil cooler fins should be cleaned when an
accumulation of debris has occurred. With the engine cold, apply cold water and compressed air to the back (engine
side) of the radiator to flush the radiator and/or oil coolers of debris.

INSPECTION

Inspect the radiator side tanks for cracks, and broken or missing fittings. Inspect the joint where the tanks seam up
to the radiator core for signs of leakage and/or deteriorating seals.

Inspect radiator core for corroded, bent or missing cooling fins. Inspect the core for bent or damaged cooling tubes.

INSTALLATION

3.7L/4.7L/5.7L ENGINE

1. Position the fan shroud over the fan blades rear-

ward towards engine.

2. Install the rubber insulators to the lower radiator

mounting features (alignment dowel and support
bracket at the lower part of the radiator).

3. Lower the radiator into position while guiding the

alignment dowel into the vertical post bracket. Posi-
tion and seat the lower radiator support bracket
onto the lower radiator closure tube.

4. Install the upper radiator mounting bolts. Tighten

bolts to 10 N·m (90 in. lbs.).

5. Connect the lower radiator hose and install the

clamp in the proper position.

6. Connect the power steering hoses to the power

steering oil cooler and install the clamps.

7. Connect the transmission oil cooler lines to the

transmission oil cooler and install the secondary
latches.

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ENGINE

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8. Position the fan shroud into the mounting clips on

the radiator tanks and secure with bolts. Tighten
the bolts to 8.5 N·m (75 in. lbs.).

9. Secure the power steering hoses into the clip on

the lower fan shroud.

10. Install the windshield washer reservoir tank and

connect the hose and electrical connector.

11. Install coolant reserve/overflow container hose(s)

to radiator filler neck and secure properly with
clamps.

12. Install coolant reserve/overflow container or degas

container to fan shroud and tighten the bolts to
8.5 N·m (75 in. lbs.).

13. Connect upper radiator hose and install clamp.

14. Install battery negative cable.

15. Fill cooling system with coolant (Refer to 7 -

COOLING - STANDARD PROCEDURE).

16. Operate the engine until it reaches normal operat-

ing

temperature.

Check

cooling

system

fluid

levels.

5.9L DIESEL ENGINE

1. Install rubber insulators to alignment dowels at

lower part of radiator.

2. Lower the radiator into position while guiding the

two alignment dowels into lower radiator support.
Different alignment holes are provided in the lower
radiator support for each engine application.

3. Install two upper radiator mounting bolts. Tighten

bolts to 11.8 N·m (105 in. lbs.) torque.

4. Connect both radiator hoses and install hose

clamps.

5. Connect transmission cooler lines to transmission

cooler. Inspect quick connect fittings for debris and
install until an audible “click” is heard. Tug on lines
to verify connection.

6. Position power steering cooler on the radiator and

tighten nuts to 10 N·m (90 in. lbs.)

7. Position fan shroud on brackets.

8. Install fan shroud mounting nut. Tighten nut to 24

N·m (18 ft. lbs.).

9. Install the coolant recovery container (Refer to 7 -

COOLING/ENGINE/COOLANT RECOVERY CON-
TAINER - INSTALLATION).

10. Position coolant recovery tank hose, washer bottle hose and the positive battery cable into the clips located on

the top of the radiator.

11. Install air box and turbocharger inlet hose. Tighten clamps to 4 N·m (35 in. lbs.).

12. Position heater controls to full heat position.

13. Fill cooling system with coolant (Refer to 7 - COOLING - STANDARD PROCEDURE).

14. Operate engine until it reaches normal temperature. Check cooling system and automatic transmission (if

equipped) fluid levels.

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