Special Tools

J 38185 Hose Clamp Pliers

Important: Always install a new set of insulators when replacing a radiator. Used insulators may be worn or too large for the new radiator. These conditions may cause the new radiator to be loose.

1. Remove the surge tank. Refer to Radiator Surge Tank Replacement.
2. Remove the clamp at the radiator inlet using J 38185 .



3. Remove the inlet hose from the radiator.
4. Remove the clamp at the radiator outlet using J 38185 .
5. Remove the outlet hose from the radiator.
6. Remove the upper air baffle assembly. Refer to Radiator Air Upper Baffle and Deflector Replacement.
7. Disconnect the automatic transmission cooler lines. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection for the Allison transmission.
8. Disconnect the engine oil cooler lines. Refer to Engine Oil Cooler Pipe/Hose Quick Connect Fitting.
9. Remove the outlet heater hose clamp at the radiator using J 38185 .
10. Remove the outlet heater hose from the radiator.



11. Remove the fan shroud bolts from the top of the radiator support.
12. Remove the upper radiator support bracket bolts. Refer to Radiator Support Replacement.
13. Remove the air cooler bolts.
14. Remove the upper transmission oil cooler bracket nuts and reposition the bracket.



15. Remove the radiator (2).
16. Remove the radiator insulators (1,3).
17. Inspect the following components. Replace the components as necessary:

•	The radiator

•	The insulators

•	The hoses and clamps

•	The mounting hardware

1. Install the radiator insulators (1,3).
2. Install the radiator (2).
3. Install the air cooler bolts.
4. Reposition the upper transmission oil cooler bracket.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

5. Install the upper transmission oil cooler bracket nuts.

Tighten
Tighten the nuts to 6 N·m (53 lb in).

6. Install the upper radiator support bracket.



7. Install the fan shroud bolts to the top of the radiator support.

Tighten
Tighten the bolts to 6 N·m (53 lb in).

8. Install the engine oil cooler lines. Refer to Engine Oil Cooler Pipe/Hose Quick Connect Fitting.
9. Install the automatic transmission oil cooler lines. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection for the Allison transmission.
10. Install the outlet hose to the radiator.
11. Install the outlet clamp to the radiator outlet using J 38185 .



12. Install the inlet hose to the radiator.
13. Install the hose clamp at the radiator inlet housing using J 38185 .
14. Install the outlet heater hose to the radiator.
15. Install the outlet heater hose clamp using J 38185 .
16. Install the surge tank. Refer to Radiator Surge Tank Replacement.
17. Install the upper air baffle assembly. Refer to Radiator Air Upper Baffle and Deflector Replacement.
18. Inspect the A/T fluid level. Refer to Approximate Fluid Capacities.
19. Inspect the engine oil level. Refer to Approximate Fluid Capacities.