Radiator: Service and Repair

Removal Procedure





1. Drain the coolant from the cooling system. Refer to Draining and Filling Cooling System.
2. Remove the upper fan shroud. Refer to Fan Shroud Replacement (Upper).
3. For the 5.7L engines, remove the upper insulators and brackets.





4. For the 6.5L and the 7.4L engines, remove the upper insulators and brackets.
5. Disconnect the upper and lower radiator hoses.
^ For the 5.7L engine, refer to Radiator Hose Replacement (5.7L).
^ For the 7.4L engine, refer to Radiator Hose Replacement (6.5L Diesel).
^ For the 6.5L (Diesel), refer to Radiator Hose Replacement (7.4L).
6. Remove the transmission fluid cooler pipes. Refer to Oil Cooler Line Replacement or Oil Cooler Line Replacement in Transmission and Drivetrain.
7. Remove the engine oil cooler pipes. Refer to Engine Oil Cooler Line Replacement.
8. Remove the lower fan shroud bolts and the lower fan shroud. Refer to Fan Shroud Replacement (Lower).
9. Disconnect the coolant recovery reservoir/surge tank hose.
^ Refer to Coolant Recovery Reservoir Replacement.
^ For diesel engines, refer to Surge Tank Replacement.





10. For the 5.7L, remove the radiator from the lower insulators and brackets.





11. For the 6.5L and the 7.4L, remove the radiator from the lower insulators and brackets.
12. Inspect all of the parts and connections for leaks and wear.
13. Replace the parts and/or connections, as necessary.


Installation Procedure





1. For the 5.7L engines, install the radiator on the lower insulators.





2. For the 6.5L and the 7.4L engines, install the radiator on the lower insulators.
3. Install the coolant recovery reservoir/surge tank hose.
^ Refer to Coolant Recovery Reservoir Replacement.
^ For diesel engines, refer to Surge Tank Replacement.

Notice: Refer to Fastener Notice in Service Precautions.

4. Install the lower fan shroud bolts and the lower fan shroud. Refer to Fan Shroud Replacement (Lower).
^ Tighten the bolts to 9 Nm (71 inch lbs.).
5. Install the engine oil cooler pipes. Refer to Engine Oil Cooler Line Replacement.
^ Tighten the fittings to 24 Nm (18 ft. lbs.).
6. Install the transmission fluid cooler pipes. Refer to Oil Cooler Line Replacement or Oil Cooler Line Replacement in Transmission and Drivetrain.
^ Tighten the fittings to 26 Nm (19 ft. lbs.).
7. Install the upper and lower radiator hoses.
^ For the 5.7L engine, refer to Radiator Hose Replacement (5.7L).
^ For the 7.4L engine, refer to Radiator Hose Replacement (6.5L Diesel).
^ For the 6.5L (Diesel), refer to Radiator Hose Replacement (7.4L).





8. For the 5.7L engines, install the upper insulators.





9. For the 6.5L and the 7.4L engines, install the upper insulators.
10. Install the upper fan shroud and the upper fan shroud bolts. Refer to Fan Shroud Replacement (Upper).
^ Tighten the bolts to 9 Nm (71 inch lbs.).
11. Refill the coolant in the cooling system. Refer to Draining and Filling Cooling System.
12. Leak test on the cooling system. Refer to Cooling System Leak Testing (Radiator Leak Test).