Ram B1500, B2500, B3500, 1999-2003

Removal & Installation

Print

  1. Disconnect both battery negative cables.
    CAUTION
    Do not remove the cylinder block drain plugs or loosen the radiator draincock with the system hot and under pressure. Serious burns from coolant can occur.

  2.  
  3. Drain the cooling system.
    CAUTION
    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 (number 6094). Always wear safety glasses when servicing constant tension clamps.


    WARNING
    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.

  4.  
  5. Remove air box and turbocharger inlet tube.
  6.  
  7. Remove coolant tank hose, washer bottle hose and the positive battery cable from the fastening clips located on top of the radiator.
  8.  
  9. Remove hose clamps and hoses from radiator.
  10.  
  11. Remove fan shroud mounting nuts from mounting brackets.
  12.  
  13. Pull shroud toward front of vehicle to clear mounting brackets
  14.  
  15. Turn shroud slightly and push toward engine to gain clearance for radiator.
  16.  
  17. Remove the power steering cooler mounting bolts and position the power steering cooler out of the way.
  18.  
  19. Disconnect the transmission cooler lines at the transmission cooler. The transmission cooler will remain on the radiator and can be removed as an assembly.
  20.  
  21. Remove the two radiator upper mounting bolts.
  22.  
  23. 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.
  24.  

To install:

  1. Install rubber insulators to alignment dowels at lower part of radiator.
  2.  
  3. Lower the radiator into position while guiding the two alignment dowels into lower radiator support.
  4.  
  5. Different alignment holes are provided in the lower radiator support for each engine application.
  6.  
  7. Install two upper radiator mounting bolts. Tighten bolts to 105 inch lbs. (11.8 Nm).
  8.  
  9. Connect both radiator hoses and install hose clamps.
  10.  
  11. 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.
  12.  
  13. Position power steering cooler on the radiator and tighten nuts to 90 inch lbs. (10 Nm).
  14.  
  15. Position fan shroud on brackets.
  16.  
  17. Install fan shroud mounting nut. Tighten nut to 18 ft. lbs. (24 Nm).
  18.  
  19. Install the coolant recovery container.
  20.  
  21. Position coolant recovery tank hose, washer bottle hose and the positive battery cable into the clips located on the top of the radiator.
  22.  
  23. Install air box and turbocharger inlet hose. Tighten clamps to 35 inch lbs. (4 Nm).
  24.  
  25. Position heater controls to full heat position.
  26.  
  27. Fill cooling system with coolant.
  28.  
  29. Operate engine until it reaches normal temperature. Check cooling system and automatic transmission (if equipped) fluid levels.
  30.  

  1. Disconnect the battery negative cable.
    CAUTION
    Do not remove the cylinder block drain plugs or loosen the radiator draincock with the system hot and under pressure. Serious burns from coolant can occur.

  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Drain the cooling system.
    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 (number 6094). Snap-On® clamp tool (number hpc-20) may be used for larger clamps. Always wear safety glasses when servicing constant tension clamps.


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

  6.  
  7. Disconnect the radiator lower hose from the radiator outlet.
  8.  
  9. Disconnect the transmission oil cooler lines from the cooler fittings. Cap the lines to prevent intrusion of foreign matter and secure the lines out of the way.
  10.  
  11. Lower the vehicle.
  12.  
  13. Remove the engine oil filler tube.
  14.  
  15. Remove the radiator upper support-to-cowl brackets.
  16.  
  17. Remove coolant reserve/overflow tank hose from radiator filler neck fitting.
  18.  
  19. Remove the windshield washer bottle.
  20.  
  21. Remove the coolant recovery bottle.
  22.  
  23. Disconnect the radiator upper hose from the radiator inlet.
  24.  
  25. Remove fan shroud mounting bolts and position shroud rearward on engine.
  26.  
  27. Remove radiator mounting bolts. Lift the radiator up and out of the engine compartment. Be careful not to damage the radiator fins or core.

    Click image to see an enlarged view

    Fig. Exploded view of the radiator (1) and fan shroud (2)

  28.  

To install:

  1. Position the fan shroud rearward on engine.
  2.  
  3. Start the radiator lower mounting bolts by hand (do not tighten).
  4.  
  5. Lower the radiator into engine compartment until the lower mounting slots rest upon the previously installed mounting bolts.
  6.  
  7. Start the radiator upper mounting bolts and tighten all mounting bolts to 95 inch lbs. (11 Nm).
  8.  
  9. Position the fan shroud on radiator flange. Tighten mounting nuts to 6 Nm (50 in. lbs.).
  10.  
  11. Raise and safely support the vehicle.
  12.  
  13. Install the radiator lower hose and clamp to the radiator outlet.
  14.  
  15. Remove protective caps from the transmission oil cooler lines. Inspect for damage and/or debris and install to cooler fittings.
  16.  
  17. Lower the vehicle.
  18.  
  19. Install the radiator upper hose and clamp to the radiator inlet.
  20.  
  21. Install the coolant recovery bottle. Engage the tab on bottom with the slot in the radiator mounting panel. Install the two mounting bolts and torque to 50 inch lbs. (6 Nm).
  22.  
  23. Connect the coolant reserve/overflow system hose to the radiator filler neck.
  24.  
  25. Install the windshield washer reservoir.
  26.  
  27. Install the radiator upper support-to-cowl brackets.
  28.  
  29. Install the engine oil filler tube.
  30.  
  31. Fill cooling system with coolant.
  32.  
  33. Operate engine until it reaches normal temperature and bleed heater hose if necessary. Check cooling system and automatic transmission fluid levels.
  34.  

3.7L, 4.7L & 5.7L Engines



  1. Disconnect the negative battery cable.
    CAUTION
    Do not remove the cylinder block drain plugs or loosen the radiator draincock with the system hot and under pressure. serious burns from the coolant can occur.

  2.  
  3. Drain the cooling system.
    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. 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 and the correct width.

  4.  
  5. Remove the hose clamps and hoses from radiator.
  6.  
  7. Remove the coolant reserve/overflow tank hose from the radiator filler neck.
  8.  
  9. Remove the coolant reserve/overflow tank from the fan shroud (pull straight up). The tank slips into slots on the fan shroud.
  10.  
  11. Unclip the power steering hoses from the fan shroud.
  12.  
  13. Disconnect the electrical connectors at the windshield washer reservoir tank and remove the tank.
  14.  
  15. Remove the fan shroud mounting bolts and pull up and out of the radiator tank clips. Position the shroud rearward over the fan blades towards engine.
  16.  
  17. Disconnect the transmission cooler lines from the transmission cooler, then plug the transmission lines and cooler to prevent leakage.
  18.  
  19. Disconnect the power steering lines from the power steering cooler, then plug the power steering lines and cooler to prevent leakage.
  20.  
  21. Remove the two radiator upper mounting bolts.
  22.  
  23. 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 retaining 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.

  24.  

To install:

  1. Position the fan shroud over the fan blades rearward towards engine.
  2.  
  3. Install the rubber insulators to the lower radiator mounting features (alignment dowel and support bracket at the lower part of the radiator).
  4.  
  5. Lower the radiator into position while guiding the alignment dowel into the vertical post bracket.
  6.  
  7. Position and seat the lower radiator support bracket onto the lower radiator closure tube.
  8.  
  9. Install the upper radiator mounting bolts. Tighten bolts to 90 inch lbs. (10 Nm).
  10.  
  11. Connect the lower radiator hose and install the clamp in the proper position.
  12.  
  13. Connect the power steering hoses to the power steering oil cooler and install the clamps.
  14.  
  15. Connect the transmission oil cooler lines to the transmission oil cooler and install the secondary latches.
  16.  
  17. Position the fan shroud into the mounting clips on the radiator tanks and secure with bolts. Tighten the bolts to 75 inch lbs. (8.5 Nm).
  18.  
  19. Secure the power steering hoses into the clip on the lower fan shroud.
  20.  
  21. Install the windshield washer reservoir tank and connect the hose and electrical connector.
  22.  
  23. Install coolant reserve/overflow container hose(s) to radiator filler neck and secure properly with clamps.
  24.  
  25. Install coolant reserve/overflow container or degas container to fan shroud and tighten the bolts to 75 inch lbs. (8.5 Nm).
  26.  
  27. Connect upper radiator hose and install clamp.
  28.  
  29. Install battery negative cable.
  30.  
  31. Fill cooling system with coolant.
  32.  
  33. Operate the engine until it reaches normal operating temperature. Check cooling system fluid levels.
  34.  

3.9L, 5.2L & 5.9L Engines



  1. Disconnect the negative battery cable.
    CAUTION
    Do not remove the cylinder block drain plugs or loosen the radiator draincock with the system hot and under pressure. serious burns from coolant can occur.

  2.  
  3. Drain the cooling system.
    CAUTION
    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 (number 6094). Snap-On® clamp tool (number hpc-20) may be used for larger clamps. Always wear safety glasses when servicing constant tension clamps.


    WARNING
    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.

  4.  
  5. Remove hose clamps and hoses from radiator.
  6.  
  7. Remove coolant reserve/overflow tank hose from radiator filler neck nipple.
  8.  
  9. Remove the coolant reserve/overflow tank from the fan shroud (pull straight up). The tank slips into T-slots on the fan shroud.

    Click image to see an enlarged view

    Fig. Remove the coolant reserve/overflow tank (4) from the fan shroud (3). The tank slips into T-slots (1) on the fan shroud

  10.  
  11. Disconnect electrical connectors at windshield washer reservoir tank and remove tank.
  12.  
  13. Remove the four fan shroud mounting bolts. Position shroud rearward over the fan blades towards engine.

    Click image to see an enlarged view

    Fig. View of the radiator support (1), radiator (2), bolts (3) and fan shroud (4)-5.9L engine

  14.  
  15. Remove the plastic clips retaining the rubber shields to the sides of radiator. Position rubber shields to the side.
  16.  
  17. Remove the two radiator upper mounting bolts.
  18.  
  19. Lift radiator straight up and 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.
    NOTE
    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.

  20.  

To install:

  1. Position fan shroud over the fan blades rearward towards engine.
  2.  
  3. Install rubber insulators to alignment dowels at lower part of radiator.
  4.  
  5. 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.
  6.  
  7. Install two upper radiator mounting bolts. Tighten the bolts to 95 inch lbs. (11 Nm).
  8.  
  9. Position the rubber shields to the sides of radiator. Install the plastic clips retaining the rubber shields to the sides of radiator.
  10.  
  11. Connect both radiator hoses and install hose clamps.
  12.  
  13. Install windshield washer reservoir tank.
  14.  
  15. Position fan shroud to flanges on sides of radiator. Install fan shroud mounting bolts. Tighten bolts to 50 inch lbs. (6 Nm).
  16.  
  17. Install coolant reserve/overflow tank hose to radiator filler neck nipple.
  18.  
  19. Install coolant reserve/overflow tank to fan shroud (fits into T-slots on shroud).
  20.  
  21. Connect the negative battery cable.
  22.  
  23. Position heater controls to full heat position.
  24.  
  25. Fill cooling system with coolant.
  26.  
  27. Operate engine until it reaches normal temperature. Check cooling system fluid levels.
  28.  

8.0L Engine



  1. Disconnect the negative battery cable.
    CAUTION
    Do not remove the cylinder block drain plugs or loosen the radiator draincock with the system hot and under pressure. serious burns from coolant can occur.

  2.  
  3. Drain the cooling system.
    CAUTION
    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 (number 6094). Snap-On® clamp tool (number hpc-20) may be used for larger clamps. Always wear safety glasses when servicing constant tension clamps.


    WARNING
    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.

  4.  
  5. Remove hose clamps and hoses from radiator.
  6.  
  7. Remove coolant reserve/overflow tank hose from radiator filler neck nipple.
  8.  
  9. The coolant recovery/reservoir does not require removal. Disconnect the overflow hose from the radiator.
  10.  
  11. Disconnect electrical connectors at windshield washer reservoir tank and remove tank.
  12.  
  13. Remove the four fan shroud mounting bolts. Position shroud rearward over the fan blades towards engine.

    Click image to see an enlarged view

    Fig. Exploded view of the radiator support (1), radiator (2), bolts (3) and fan shroud (4)-8.0L engine

  14.  
  15. Remove the two radiator upper mounting bolts.
  16.  
  17. Lift radiator straight up and 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.
    NOTE
    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.

  18.  

To install:

  1. Position fan shroud over the fan blades rearward towards engine.
  2.  
  3. Install rubber insulators to alignment dowels at lower part of radiator.
  4.  
  5. Lower the radiator into position while guiding the two alignment dowels into lower radiator support.
  6.  
  7. Different alignment holes are provided in the lower radiator support for each engine application.
  8.  
  9. Install two upper radiator mounting bolts. Tighten bolts to 95 inch lbs. (11 Nm).
  10.  
  11. Connect both radiator hoses and install hose clamps.
  12.  
  13. Install windshield washer reservoir tank.
  14.  
  15. Position fan shroud to flanges on sides of radiator. Install fan shroud mounting bolts and tighten to 50 inch lbs. (6 Nm).
  16.  
  17. Install coolant reserve/overflow tank hose to radiator filler neck nipple.
  18.  
  19. Connect the overflow hose to the radiator.
  20.  
  21. Install the negative battery cables.
  22.  
  23. Position heater controls to full heat position.
  24.  
  25. Fill cooling system with coolant.
  26.  
  27. Operate engine until it reaches normal temperature. Check cooling system fluid levels.
  28.  

 
label.common.footer.alt.autozoneLogo