2nd Gen Non-Engine/Transmission Radiator replace tips???

[Texis]

About to swap out the radiator on the 97, old one pee'in everywhere. Also have a new fan clutch going in while I'm there. 14 years is long enough for any radiator!



Any tips on this little job? Looks farily straightforward, but I know many of you have "been there, done that" and may have a short cut or two for me.



Thanks Guys.

 

[Grey Wolf]

Sounds like you are well prepared already, your right it's no big deal. The only thing I could add is I like ES Compleat for coolant but Zerex is a good second choice.



ES Compleat?



http://www.valvoline.com/pdf/zerexg05.pdf



What about the condition of all your coolant hoses?

 

[tolmsted]

What about the condition of all your coolant hoses?

Grey Wolf, you have a very good thought. Top & Bottom hose and don't forget the heater hoses also. Not hard to do at all while he's in there with the system drained. Go for it Texis !!!!

 

[Texis]

Hoses are good, they are only 7 or 8 years old :-O. . I haven't gotten my money's worth yet



So what is the correct order to remove this stuff? appears the fan & clutch need to be unbolted and left in the shroud... then remove radiator + shround all at once??



I am considering modifying the bottom section of the shroud (while it is out) in case I ever want to change the fan clutch again... without having to yank half the front end out!



Does the radiator have any bolts on the bottom holding it in place, or is it just sitting in rubber mounts with only the top 2 bolts holding it?

 

[GOlsen]

So what is the correct order to remove this stuff? appears the fan & clutch need to be unbolted and left in the shroud... then remove radiator + shround all at once??

Exactly what I did, worked very well for me.

 

[Grey Wolf]

Squeeze the hoses, if you hear some creaking and groaning toss um out



Modify the shroud, well I would leave it alone, but that's me. It's complete around the fan for a reason. .



Your right they (radiator) sit in a rubber donut at the bottom.



One other thing I would drain the radiator through the bottom hose, sometimes the pet cocks can be a pain!



Just had a thought don't forget the T-Stat (get a Cummins stat if needed), and check the weep hole on the water pump while it's easy to see!

 

[Texis]

Found the leak. The end tanks are plastic and one of them had several cracks in it. Just an age issue. I will add that when I inspected the old radiator I did find that it was clogged severly. The truck wasn't over heating, I guess the huge 4 core units in these trucks have can handle a fair amount of blockage.



Here's what I did;



1) Removed the bottles (wiper & overflow)

2) Took the bolts out of the shroud and moved it back and out of the way.

3) Removed the radiator.



The wiper bottle was the worst part of this bit of wrenchin. Took awhile to figure out that the bottle needed to be pryed away from the shroud... so the little round buttons would clear, out it finally came.



Here's where I stalled;



The freakin nut on the fan clutch. The book states that it is a left handed thread. I tried to use a marine gland packing wrench (thin)... but nothing doin! That baby is TIGHT and the el cheapo wrench is spreading.



Suppose I will head down to the auto store and buy a 36mm wrench. Any ideas on getting that turd off?



Thanks

 

[GOlsen]

To get the fan off, I unbolted the whole assembly from the front of the engine. I think it has 3 or 4 bolts that hold it on.

 

[ed9824v]

I have done two and never took the fan off to replace the radiator.

 

[GOlsen]

I have done two and never took the fan off to replace the radiator.

Yeah I was thinking about that. I don't think it is required. I happened to do my radiator the same time I did the KDP.

 

[snappy]

Lisle 43300. Use it with an air hammer and leave the serpentine belt on till after the fan is removed.

 

[Texis]

Lisle 43300

Nice. Exactly what I need. I suppose the notch in the handle end is for a V blade in an air chissle? Everything online appears to be only sold in sets... $120-$140 bucks! Hopefully the local auto shop will sell a 36mm seperately??... or rent/loan one.



At least I know what I'm looking for! Thanks.

 

[Grey Wolf]

I use the fan wrench and a shot of penetrant, The handle is long enough that I can wrap it with a single jack once and it's loose. .

 

[Texis]

DONE.



The air chissel is the shizzle (couldn't resist).



I used the Auto shop loaner fan clutch wrench set. I tried with everything I had to move the nut by hand (6'4" 250lbs) and no go... tried the 4lb hammer, still nada. Then I pulled out my air chissel, used a grinder to put a 1/4" notch the blade, keyed it onto the rental tool handle and "BINGO"... . bout a 5 second air burst did the trick. Followed by that certain feeling of mechanical victory.



Nice to sit in 103 degree Texas with the AC on max re-circ for an hour and the needle never moves above 130, the new radiator barely even gets warm.



Thanks for the help and tips. Now I'm ready to tow the tractor to the deer lease in this horrible heat!!

 

[LandShark]

I use a long drift pin and a hammer to get the big nut off. Just give the edge of the nug a good rap and it will come right off. No need for any special tools.