Radiator removal questions

irunmiles · **Posted:** Sat Dec 03, 2011 6:43 pm

I replaced my fan clutch today and after I took it for a test drive I noticed coolant dripping from the bottom of the radiator. I undid what I had just finished and removed the shroud, fan and clutch, to discover a coolant trickle from the engine-side center of the fins on the radiator. There is no visual damage to the outside of the radiator, so why is it leaking from this very obvious spot? The only thing that I did to the radiator is loosen the two small bolts on either side at the top to tip it forward a bit while I replaced the fan clutch. I have 185k miles on the rig and the coolant is coming out clean.

I can order a life time replacement radiator a AutoZone for $167. How does the old radiator come out? I see the four coolant hoses, but only found the two top bolts. It looks like the bottom rests on rubber bumpers. Also, what is the finned radiator-looking device in front of the radiator, and is it attached to the radiator? Should I replace my orginal coolant hoses while I'm at it?

papaindigo · **Posted:** Sun Dec 04, 2011 12:16 pm

I'm not exactly sure how to remove the radiator. The FSMs posted on Sams NOOB guide give instructions but I don't quite believe all of the instructions especially the "remove the grill" step. What is obvious is you need to remove the fan shroud and the mechanical fan on the front of the engine; drain the radiator; remove the hoses going to the radiator (you mention 4 but I only see 3-upper on passenger side running to radiator for tstat, lower on driver's side below the intercooler hose which you will have to remove to get to that lower radiator hose, and the overflow hose running across the top of the fan shroud from the upper driver's side of the radiator). After that I suspect there are a couple of bolts holding the radiator at the top and that the bottom is held in place by the pins shown in the FSM; if that's the case undo the bolts and I'd guess the radiator simply pulls up and out.

The finned thing in front of the radiator is the intercooler (I suspect what you think is that 4th radiator hose is an intercooler hose) and it's not connected to the radiator.

I wouldn't bother to replace the coolant hoses personally. Modern hoses on diesel engines seem to last forever. That said the lower radiator hose appears to be a real bear to get to so if you want to do any hose I'd just do that one while you have the radiator out and can get to the lower hose. A Gates lower radiator hose is Gates # 23071.

DynoPax · **Posted:** Sun Dec 04, 2011 12:27 pm

You may have nicked the rad when removing the clutch, same happened to me last year... Pulled the rad out and had it fixed for $50.

Best way I found is to remove front grill, then front top crossmember. The hood latch cabling can remain attached, there is enough play to drop the crossmember on top of the engine and out of the way. From the engine side toward the front, you have the radiator, then intercooler (CAC) and finally AC/tranny oil cooler.

I do not exactly recall all fastenings between rad and CAC but I did remove the front electric fan and any bolts on either side of cooling assemblies. Be particularily careful not to loose the nut insert on the rad. These are simply slid into their holders and can easily fall off, hence a hard time finding them on the ground or having to find proper replacement :banghead:

To free the rad, you have to pull slightly (and carefully!) the whole cooling contraption to clear the bottom seat inserts from the frame, then only pull the CAC/AC coolers a tad bit more up, as they lay on top of the rad seats. Pics would be more helpful, but I have none. You may do a quick search on the forum that will turn up successful. Hope this helps!

irunmiles · **Posted:** Sun Dec 04, 2011 12:36 pm

Thanks for the replies. I have a new rad and lower hose ordered. I probably did nick it during fan removal. Didn't know they are so fragile. Learned a lesson.

Radiator removal questions

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