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Old 03-09-2010, 12:53 AM   #2
Durallymax

Name: Durallymax
Title: Diesel Enthusiast
Status: Not Here
Join Date: Sep 2007
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Posts: 224
Radiator Stack Removal
1.Now its time to get messy. First we will remove the drivers side CAC tube. To do this you will need to disconnect the long 90* silicone elbow from the turbo as well as the aluminum section of the CAC tube on that side using an 11mm deep well then remove this from the truck and set aside. Next remove the clamp that holds the other side of the aluminum section to the elbow on the intercooler using an 11mm deep well. I like to leave the elbow on the intercooler to make reinstallation easier.
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2.Now you need to remove the passenger side CAC tube. To do this remove the band clamp at the intake bridge of the motor using an 11mm deep well. On this side I like to remove the elbow from the intercooler as it makes it easier to remove the radiator hose later on. But leave it connected to the CAC tube for easier reinstallation. Again remove the clamp using an 11mm deep well socket. Then fish the tube out and set aside.
Click the image to open in full size.
3.Now lets get the tranny cooler out of the way. The first step is to remove the lines from it. To do this slide the pastic covers off of the fittings then using a small scredriver or pick, remove the little clips that hold the lines into the fittings. Now pull the lines out and use a small cup to catch the oil that drains out, it isn’t much but enough to make a small mess. Next reinstall the little clips back into the trans cooler fittings. The lines will push back in without removing the clips upon reinstallation, plus this way you dont loose them. Now remove the two bolts that fasten the cooler to the A-frame brace using a 10mm and then remove the two body clips that also support it. Now pivot it out and set aside. It will continue to drain out some fluid just so you know.
4.Now you can remove the big A-Frame brace using a 10mm to remove the 2 bolts at the bottom of each leg and the 2 bolts at the top that hold it to the radiator support. Youll need to come in from the rear. The picture below shows it removed but you can see the outline of where it once was.
Click the image to open in full size.
5.Now you will to get the A/C condensor out of the way. If you have a refrigerant service machine, evacuate the A/C system at this point. Then unbolt the lines from the A/C condensor then remove the two mounting bolts with a 10mm and remove it from the truck. If you do not have a refridgerant service machine, just remove the two mounting bolts and then swing the condensor out of the way. It may be neccessary to slightly bend the lines to get adequate clearance later on in the removal process.
Click the image to open in full size.
6.Lets get the radiator disconnected starting with the hoses. Removing the driver side radiator hose, remove it completely from the engine by removing both of the clamps and set aside. Next remove the lower radiator hose but leave it attached to the water pump as it is easier to get off with the radiator out of the way, you may want to set a catch pan under the hose as it will puke out some coolant. Now you will want to remove the two tranny cooler lines that run into the radiator in the same fashion as the others. Now remove the coolant overflow hose from the radiator as well.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
7.Now we need to remove the radiator top brace. Start by removing the cross brace that runs over the drivers side battery using a 10mm. Next remove the 3 bolts on the underside of it at each end using a 10mm. Now you can either leave it attached to the radiator stack or remove the two bolts that hold the assembly to the brace using a 13mm.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
8.Now we can finesse the radiator/intercooler out of the truck. But, first remove the drain plug once more and have somebody channel the coolant as you tilt the radiator to drain the remaining coolant out. Swing the a/c condenser to the side to make some room. Now remove the assembly and set to the side.
Click the image to open in full size.
9.Now the lower fan shroud can just be pulled out and set aside. See Picture Above.
10.You can also remove the lower radiator hose now from the water pump using a 5/16” or 8mm. Removing the splash gard with a 15mm (5 bolts) will get it out of the way so a bucket can catch the coolant. Also remove the heater hose from the aluminum heater line on the passenger side of the engine. And since we are removing heater lines, do up to the top of the engine back by the firewall and disconnect the heater lines.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
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