Chrysler Full-Size Trucks 1989-1996 Repair Guide

Hoses

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INSPECTION



See Figures 1, 2, 3 and 4


CAUTION
On models equipped with an electric cooling fan, disconnect the negative battery cable or fan motor wiring harness connector, before replacing any radiator/heater hose. The fan may come on, under certain circumstances, even though the ignition is OFF.

Upper and lower radiator hoses along with the heater hoses should be checked for deterioration, leaks and loose hose clamps at least every 15,000 miles (24,000 km). Early spring and at the beginning of the fall or winter, when you are performing other maintenance, are good times to perform the inspection. Make sure the engine and cooling system are cold. Visually inspect for cracking, rotting or collapsed hoses, replace as necessary. Run your hand along the length of the hose. If a weak or swollen spot is noted when squeezing the hose wall, replace the hose.



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Fig. Fig. 1: The cracks developing along this hose are a result of age and hardening



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Fig. Fig. 2: A hose clamp that is too tight can cause older hoses to separate and tear



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Fig. Fig. 3: A soft, spongy hose like this is identifiable by the swollen section near the clamp.



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Fig. Fig. 4: Debris in the coolant can weaken the hose from the inside

REMOVAL & INSTALLATION



See Figures 5 and 6


CAUTION
Never remove the pressure cap while the engine is running or personal injury from scalding hot coolant or steam may result. If possible, wait until the engine has cooled to remove the pressure cap. If this is not possible, wrap a thick cloth around the pressure cap and turn it slowly to the stop. Step back while the pressure is released from the cooling system. When you are sure all the pressure has been released, still using the cloth, turn and remove the cap.



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Fig. Fig. 5: Lift the lever, if so equipped, to release the system pressure



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Fig. Fig. 6: Remember to close the drain valve before refilling, be careful not to overfill the radiator and secure the cap when finished

  1. Drain the cooling system into a suitable container (if the coolant is to be reused, make sure the container is clean) by loosening the draincock on the bottom of the radiator.
  2.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Loosen the hose clamps at each end of the hose that requires replacement.
  2.  
  3. Twist, pull and slide the hose off the radiator, water pump, thermostat or heater connection.
  4.  

If the hose is stuck at the connection, do not try to insert a screwdriver or other sharp tool under the hose end in an effort to free it, as the connection and/or hose may become damaged. Heater connections especially may be easily damaged by such a procedure. If the hose is to be replaced, use a single-edged razor blade to make a slice along the portion of the hose which is stuck on the connection, perpendicular to the end of the hose. Do not cut deep so as to prevent damaging the connection. The hose can then be peeled from the connection and discarded.

  1. Clean both hose mounting connections. Inspect the condition of the hose clamps and replace them, if necessary.
  2.  

To install:
  1. Dip the ends of the new hose into clean engine coolant to ease installation.
  2.  
  3. Position the clamps on the new hose.
  4.  
  5. Coat the connection surfaces with a water resistant sealer and slide the hose into position. Make sure the hose clamps are located beyond the raised bead of the connector (if equipped) and centered in the clamping area of the connection.
  6.  
  7. Tighten the clamps to 20-30 inch lbs. (2-3 Nm). Do not overtighten.
  8.  
  9. Be sure the radiator draincock is closed, then fill the cooling system.
  10.  


CAUTION
If you are checking for leaks with the system at normal operating temperature, BE EXTREMELY CAREFUL not to touch any moving or hot engine parts. Once temperature has been reached, shut the engine OFF, and check for leaks around the hose fittings and connections which were removed earlier.

  1. Start the engine and allow it to reach normal operating temperature. Check for leaks.
  2.  

 
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