The process of removing and replacing a radiator in a 1989 Dodge Dakota truck is not as difficult a task as it may seem. Even a woman can do this job. It’s a major repair that could cost you hundreds of dollars, but knowing is half the battle. This is a step-by-step account of the removal and replacement of that radiator.
You will need the following tools:
- 3/8 “dual drive ratchet
- 3/8 to 1/4 “adapter
- curve
- flat head screwdriver
- 7/16 “x 1/4” cup
- 1/2 “x 1/4” socket
- 6 “x 1/4” extension
Step 1.
Raise the hood of the truck and place the attachment in the slot in the hood to secure it in place. If the radiator has water or coolant in it, you will need to drain it. Do this by placing the drain pan under the left side of the radiator and locating the drain plug on the bottom of the radiator. It doesn’t come out, it just loosens to allow the water to drain off. Once the water and coolant have been drained, locate the hose that runs from the top of the radiator to the reservoir. Remove the hose from the radiator but leave it connected to the reservoir.
Step 2.
Locate the 2 clamps that hold the radiator to the body. These will be located at the top of the radiator where the radiator touches the body. Remove these 2 clips with the flathead screwdriver and place them to the side or above the vent so they won’t get lost.
Step 3.
Find the 2 bolts that connect the shroud to the radiator. You will find them a little more than halfway up the back on each side of the radiator. The bolt on the right, below the fill spout, is easier to reach and can be removed from the top. The other side will require you to lie on your back on the ground and use the ratchet with an extension of at least 6 “long. Place your 3/8” to 1/4 “adapter into the ratchet. Pop the 7/16 “x 1/4” plug into the adapter and remove the bolt on the right, then remove the plug and place the extension on the adapter and place the plug on the extension. Remove the other bolt on the left side of the radiator.
Step 4.
Lie on the ground on your back and locate the 2 transmission cooler lines at the bottom of the radiator. You will find one on each side of the radiator at the bottom. Place the drain pan under the radiator. Using the flat blade screwdriver, loosen the clamp screw that holds the rubber line on the fixture. Take the pliers and squeeze the rubber hose and move it around the fitting and pull back at the same time. These aren’t easy to remove, but you don’t want to cut the hose unless it’s split. Keep trying because it will take a couple of minutes of maneuvering to remove them.
Step 5.
While still lying on the ground, locate the lower radiator hose. Again, take the screwdriver and loosen the screw that holds the clamp in place. With both hands, twist and pull up and down the hose until it is free. The water will come out of this hose because it goes to the motor. Let it drain into the drain pan.
Step 6.
At the top of the radiator, locate the 2 bolts that hold the radiator to the body. Use the 1/2 “x 1/4” socket from the ratchet and remove them. Put them in the same place where you put all the other bolts and clips. Hold the radiator on each side and pull it out of the cavity.
Step 7.
Remove the 2 rubber bumpers that the old radiator top bolts went through. Remove the same 2 bumpers on the new radiator and put the old ones in place. If you noticed, the new ones were wider than the old ones and didn’t allow the bolt to reach into the truck body. Hold the new radiator in exactly the same way as you did the old one to remove it. Now put the new one in the cavity and make sure the bottom tabs are in the slots they belong to at the bottom.
Step 8.
Start at the bottom of the radiator and reconnect all the hoses. To do this, smear a small amount of transmission fluid on the cooler line fittings and push the line back into the fitting. Tighten the clamp screw with the screwdriver. No fluid is needed for the lower radiator hose. Slide it over the accessory and tighten the clamp screw with the screwdriver. Make sure these hoses are tight so there are no leaks.
Step 9.
Locate the bolts that came out of the sides of the radiator and replace them using the same socket and ratchet combination that you used to remove them.
Step 10.
At the top of the radiator, replace the upper radiator hose and tighten the clamp. Make sure it’s tight so it doesn’t leak. Replace the 2 clips that came out of the slots at the top. Now replace the 2 bolts on top with the same combination you used when removing them. Put 1 gallon of antifreeze and coolant in the radiator. Fill the rest of the way with water.
Step 11.
Start the truck. It should heat up quickly. As the water in the radiator goes down, the more in the radiator. It will cool the radiator quickly and close the thermostat. Let the temperature rewarm. This will cause the water in the radiator to drain out. Just put your hand on the spout and try to avoid losing a lot of water. When it has warmed up, refill the radiator with water. Put the radiator cap on the spout and you’re ready for the road once again.
This procedure should not take more than 40 minutes in total. In less than an hour he removed his old radiator and replaced it with a new one. The exact same job that a shop would charge you $ 250 for you and it only cost you a little time and a gallon of antifreeze and coolant plus the cost of the radiator. You saved yourself no less than $ 100.