Chrysler Full-Size Trucks 1997-2000 Repair Guide

Radiator

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Procedures will vary depending on model and equipment fitted.


CAUTION
NEVER open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Avoid physical contact with the coolant. Wear protective clothing and eye protection. Always drain coolant into a sealable container. Clean up spills as soon as possible. Coolant can be reused if it's reasonably clean and free of debris. If you suspect it is contaminated, or is more than a couple years old, it should be replaced.

REMOVAL & INSTALLATION



  1. Disconnect the battery negative cable(s).
  2.  
  3. Drain the radiator.
  4.  
  5. Remove any cables or lines clipped to the radiator or shrouds.
  6.  
  7. Remove the upper and lower heater hoses.
  8.  


WARNING
Most cooling system hoses use "constant tension" hose clamps. When removing or installing, use a tool designed for servicing this type of clamp. The clamps are stamped with a letter or number on the tongue. If replacement is necessary, use only an OEM clamp with a matching ID.


CAUTION
Always wear safety glasses when servicing constant tension clamps.

  1. If coolant overflow and windshield washer fluid bottles are fitted to the fan shroud, disconnect the lines and remove them. Pull straight up to remove the bottles from shroud.
  2.  
  3. On 4.7L models, remove the upper fan shroud. Disconnect the electric fan wiring.
  4.  
  5. On 2.5L models, disconnect the fan wiring, remove the fan and shroud hardware and remove the assembly.
  6.  
  7. On other models, remove the fan shroud hardware and reposition the shroud towards the engine for access to the radiator.
  8.  
  9. Label, then disconnect the automatic transmission lines if the fluid cooler is incorporated into the radiator. Plug the lines to prevent spillage. Be sure to note which line goes to which fitting.
  10.  
  11. On Durango, remove the grill.
  12.  
  13. Check for rubber shields on the sides of the radiator. Remove them if fitted. These are normally secured with non-reusable plastic pins.
  14.  
  15. Remove the radiator bolts (usually two at the top). Lift the radiator up and out of the vehicle, being careful that the cooling fins do NOT bang against anything. They are easily damaged.
  16.  
  17. Some vehicles may have an auxiliary automatic transmission fluid cooler which will come away with the radiator.
  18.  



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Fig. Size marking on constant tension clamps (1)



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Fig. Coolant bottle T-slots and studs



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Fig. Shroud assembly (4.7L): Radiator (1), Fan (2), Upper Shroud (3), Bolts (4), Lower Shroud (5)



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Fig. Mark automatic transmission oil cooler lines before disconnecting. Supply (1) and return (2) lines in this illustration for the 4.7L engine



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Fig. Plug the transmission lines to prevent leakage



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Fig. Radiator mounting bolt

To install:

  1. Lower the radiator into place. There are two alignment pins at the bottom that fit into holes in the lower support.
  2.  
  3. Tighten radiator mounting bolts to 17 ft. lbs. (23 Nm).
  4.  
  5. The remainder of the procedure is the reverse of removal. Double-check the connection of all hoses and lines before adding fluids or operating the vehicle.
  6.  

 
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