The process of removing and replacing a radiator on a 1989 Dodge Dakota pickup is not as difficult a task as it sounds. Even a woman can do this job. It’s a major repair that could cost you hundreds of dollars, but knowing it 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″ double drive ratchet
- Adjustment from 3/8 to 1/4″
- curve
- flat head screwdriver
- 7/16″ x 1/4″ socket
- 1/2″ x 1/4″ socket
- 6″ x 1/4″ extension
Step 1.
Raise the hood of the truck and place the strut into 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 at the bottom of the radiator. It does not come out, it is simply loosened to let the water drain. After the water and coolant have been drained, locate the hose that runs from the top of the radiator to the reservoir. Pull the hose off 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 position them to the side or above the vent so they don’t get lost.
Step 3.
Locate the 2 bolts that connect the shroud to the radiator. You’ll find them a little more than halfway down the back of each side of the radiator. The bolt on the right, below the fill spout, is the easiest 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 that is at least 6″ long. Put your 3/8″ to 1/4″ adapter into the ratchet. Pull out the 7/16″ x 1/4″ socket on the adapter and remove the bolt on the right, then remove the socket and put the extension on the adapter and put the socket 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’ll find one on each side of the radiator at the bottom. Place the drain pan under the radiator. Using the flathead screwdriver, loosen the clamp screw that holds the rubber line to the fitting. 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 into the hose unless it’s split. Keep trying because it will take you a couple of minutes to maneuver to get them out.
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. Using both hands, twist and pull up and down on the hose until it is free. Water will come out of this hose because it goes to the engine. 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 on the ratchet and remove them. Put them in the same place where you put all the other bolts and clips. Grasp the radiator on each side and pull it out of the cavity.
Step 7.
Remove the 2 rubber bumpers that the top bolts went through on the old radiator. Remove the same 2 bumpers from the new radiator and put the old ones in their place. If you noticed the new ones were wider than the old ones and would not allow the bolt to reach the truck body. Hold the new radiator exactly the same way you did the old one to remove it. Now put the new one into the cavity and make sure the bottom tabs are in the slots where they belong on the bottom.
Step 8.
Start at the bottom of the radiator and reconnect all the hoses. To do this, spread a small amount of transmission fluid on the cooler line connections and push the line back into the connection. 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 you used when removing them.
Step 10.
At the top of the radiator, reattach the upper radiator hose and tighten the clamp. Make sure it’s tight so it doesn’t slip out. 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, more goes into the radiator. It will cool the radiator quickly and close the thermostat. Let the temperature rise again. This will cause the water in the radiator to be expelled. Just put your hand over the spout and try to keep it from losing too much water. When it has warmed up, refill the radiator with water. Put the radiator cap back on the spout and you’re ready to hit the road once again.
This procedure should not take more than 40 minutes total time. In less than an hour you removed your old radiator and replaced it with a new one. Exactly the same job that a shop would charge $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 no less than $100.