OEM 2004 Dodge Ram 3500 Radiator

2004 Dodge Ram 3500 Radiator Parts and Q&A

• Q: How to Maintain and Fix a Radiator on a 5.9L Diesel Engine on 2004 Dodge Ram 3500?

  A: First, disconnect both of the battery negative cables to protect yourself from burns when servicing the radiator in your 5.9L diesel engine. To drain the cooling system, use only the proper tools made for constant tension hose clamps along with safety glasses. Any time you have to replace spot welding clamps, choose clamps that have the same numbers or letters as the old ones. Unfasten the air box and turbocharger inlet tube, disconnect the coolant tank hose, the washer bottle hose and the positive battery cable from the radiator's clips. Take the hose clamps off the radiator and then remove the bolts holding the power steering cooler to the radiator, placing the cooler to the side. Take out the cooler lines from the transmission, making sure the cooler itself is still attached to the radiator. Take out the electrical connector for the electronic viscous fan drive, then use a fastener removal tool to push out the two push pins and the lower shroud assembly together with the fan drive wiring, taking care not to harm anything. Unfasten the wiring harness bracket from the upper fan shroud and afterward, take out both of the upper bolts securing the radiator. Pull the radiator from the engine compartment by lifting straight up so that you don't damage the cooling fins or tubes. To enhance heat transfer, rinse the radiator fins with cold water and apply compressed air to them. Don't forget to look at the side tanks for damages and check the core for bent or corroded fins and pipes. To install the radiator, fit the rubber insulators on the alignment dowels at the lower part, lower it and secure it with the two upper bolts tightened to 11.8 Nm (105 inch lbs.). Hook up the radiator hoses and seal them with the clamps and after that, install the transmission cooler lines, making sure the quick connects are not dirty and are correctly attached. Raise the power steering cooler above the radiator and tighten all the screws until they reach 10 Nm (90 inch lbs.). Put the electronic viscous fan wires in the upper channel and insert the grommet carefully, then set the lower shroud in place with two push pins to be sure the wiring isn't trapped. Put the wiring harness bracket back on the upper shroud, attach the viscous fan drive harness and place the coolant recovery container. Next, place the coolant recovery tank hose, washer bottle hose and positive battery cable into the clips on the radiator, insert the air box and turbocharger inlet hose with tightened clamps, set the heater to full heat, fill the engine's coolant and power the car until everything has warmed up while checking the fluid in the cooling system and transmission.