C. Replace Radiator (BR Trucks)

1. With the ignition key in the OFF position, disconnect the battery.

NOTE:
Disconnect BOTH negative battery cables on Cummins Diesel Engine equipped trucks.

Note:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure.

2. For Diesel engine equipped trucks: Remove the nuts that retain the positive battery cable to the top of the radiator then position the positive battery cable toward the rear.

WARNING:
DO NOT REMOVE THE CYLINDER BLOCK PLUG OR THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR.

3. Without removing the radiator pressure cap and with the system not under pressure, open the radiator draincock by turning it counterclockwise.

4. After the coolant reserve tank has emptied, remove the radiator pressure cap and continue draining the radiator. Save the coolant for later reuse.

5. Remove the upper radiator hose from the radiator.

6. Disconnect coolant reserve/overflow tank hose from radiator fill neck nipple.

7. For Diesel engine equipped trucks: Remove the coolant reserve/overflow tank from the fan shroud by pulling straight up.

8. Disconnect the remove the washer pump from the windshield washer reservoir tank, then drain and remove the tank.

9. Remove the two metal clips retaining the upper part of the fan shroud to the top of the radiator.





10. Remove the four fan shroud mounting bolts (Figure 5). Move the shroud rearward over the fan blades toward the engine.

11. Remove the lower radiator hose.

12. For 8.0L V10 engine equipped trucks: Disconnect and cap the automatic transmission hoses, if equipped.

NOTE:
Be careful not to lose the spacer when removing the quick connects.





13. Remove the two upper radiator mounting bolts (Figure 6).

14. Lift the radiator straight up and out of the engine compartment and DESTROY THE RADIATOR BY PUNCTURING SEVERAL OF THE CORES. REMOVED RADIATORS MUST NOT BE REUSED!

15. Transfer the two upper radiator mounting bolt grommets from the removed radiator to the new radiator.

16. Lower the new radiator into position while guiding the two alignment dowels into the lower radiator support.

17. Install the upper radiator mounting bolts. Tighten the screws to 95 in-lbs (11 N.m).

18. Install the fan shroud. Tighten the retaining screws to 50 in-lbs (5.4 N.m).

19. Install the windshield washer reservoir bottle and install the washer pump.

20. Install the upper and lower radiator hoses. Align the hoses and position the clamps so they will not interfere with the engine or the hood.

21. For 8.0L V10 equipped trucks: Connect the automatic transmission hoses, if equipped.

22. Install the metal clips to the top of the fan shroud.

23. Install the coolant reserve/overflow tank hose to the radiator filler neck nipple.

24. For Diesel engine equipped trucks: Install the positive battery cable to the top of the radiator.

25. Connect the negative battery cable(s).

26. Fill the radiator with the original coolant until full and fill coolant reserve bottle to at least the FULL mark.

NOTE:
Be careful not to spill coolant on the drive belts or the generator.

27. Operate engine until it reaches normal operating temperature. Check cooling system and automatic transmission for leaks and proper fluid levels. Adjust as necessary.