1996 Model Year Dodge Ram (BR) Trucks Equipped With a 8.0L V-10 or Cummins Diesel Engine ("W'' or "C" in the 8th VIN Position) Built at the Lago Alberto Assembly Plant ("M" in the 11th VIN Position) From April 24,1996 Through May 24, 1996 (MDH 042423 Through MDH 052400)

Service Procedure Videotape

No videotape of the service procedure for this notification will be provided.

Dealer Notification & Vehicle List

Involved dealers: Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a copy of this dealer notification letter and a list of the involved vehicles by first class mail.

The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles.

All other dealers: Each Dodge and Chrysler-Plymouth dealer who does not receive a Vehicle List will receive a copy of this dealer notification letter by first class mail.

DIAL System Functions 53, 70 and VIP

All involved vehicles will be entered to DIAL System Functions 53, 70 and VIP at the time of notification mailing for dealer inquiry as needed.

Parts

Due to the small number of involved vehicles, no parts will be distributed initially to dealers. Parts should only be ordered after inspection determines replacement to be necessary.

IMPORTANT: Each vehicle should be inspected before a replacement radiator is ordered. ONLY 35-40% OF INVOLVED VEHICLES ARE EXPECTED TO REQUIRE RADIATOR REPLACEMENT.

Refer to the table below for the appropriate radiator assembly:

Owner Notification and Service Scheduling

All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers. A copy of the owner notification letter is attached.

Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed.

Service Procedure

A. Inspect Radiator Build Date Code:

1. Locate the radiator build date code as shown in Figure 1.

2. _ If the build date code is 1166 through 1296, the radiator must be replaced.Continue with Section B (PL) or Section C (BR).

_ If the build date code is not in the above range, no further action is necessary

B. Replace Radiator (PL Vehicles):

1. With the ignition key in the OFF position, disconnect the battery.

Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.)when you have completed the service procedure.

WARNING: DO NOT REMOVE THE CYLINDER BLOCK PLUG OR THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR.

2. Without removing the radiator pressure cap and with the system not under pressure, open the radiator draincock by turning it counter clockwise.

3. After the coolant reserve tank has emptied, remove the radiator pressure cap and continue draining the radiator. Save the coolant for later reuse.

4. Remove engine air inlet duct.

5. Remove the upper radiator hose from the radiator.
6. Disconnect and cap the automatic transmission hoses, if equipped.
7. Remove the radiator to battery strut and body ground wire (Figure 2).
8. For vehicles equipped with a DOHC engine: Remove the battery and battery tray.
9. Disconnect the radiator fan module electrical connector(s).
10. Remove the fan shroud retainers at the top of the shroud (Figure 3).
11. Lift fan shroud up and out of bottom shroud attachment clips.
NOTE: For vehicles with the DOHC engine: Remove the left fan first and then remove the right fan.
12. Remove the lower radiator hose.
13. Remove the upper radiator isolator bracket mounting screws(Figure 2).
14. Disconnect the engine block heater wire, if equipped.
15. Remove the air conditioning condenser attaching screws, if equipped (Figure 4), then lean the condenser forward.
NOTE: It is not necessary to discharge the air conditioning system to remove the radiator.
16. Lift the radiator from the engine compartment and DESTROY THE RADIATOR BY PUNCTURING SEVERAL OF THE CORES. REMOVED RADIATORS MUST NOT BE REUSED!
17. Transfer the lower radiator isolators from the removed radiator to the new radiator.
18. Slide the new radiator into position behind the radiator support.
19. Attach the air conditioning condenser, if equipped (Figure 4). Tighten the mounting screws to 50 in-lbs (5.4 N m).
20. Seat the radiator assembly lower rubber isolators into the mounting holes in thel ower crossmember.
21. Install the upper radiator isolator mounting bracket screws. Tighten the screws to 65in-lbs. (7.4 Nm).
22. Install the lower radiator hose. Align the hose and position the clamp so it will not interfere with the engine.
23. Connect the automatic transmission hoses, if equipped. Tighten the hose clamps to35 in-lbs. (4 Nm).
24. Slide the cooling fan module into the clips on the lower radiator flange (Figure 3).
NOTE: For vehicles equipped with a DOHC engine: Install the right fan module first and then the left fan module.
25. Install the fan module retaining screws and tighten to 50 in-lbs. (5.4 N m).
26. Connect the cooling fan motor electrical connector (s).
27. Install the upper radiator hose. Align the hose and position the clamp so it will not interfere with the engine or the hood.
28. For vehicles equipped with a DOHC engine: Install the battery and battery tray.
29. Connect the negative battery cable.
30. Fill the radiator with the original coolant until full and fill coolant reserve bottle to at least the FULL mark.
NOTE: Be careful not to spill coolant on the drive belts or the generator.
31. Operate engine until it reaches normal operating temperature. Check cooling system and automatic transmission for leaks and proper fluid levels. Adjust as necessary.

C. Replace Radiator (BR Trucks):

1. With the ignition key in the OFF position, disconnect the battery.
NOTE: Disconnect BOTH negative battery cables on Cummins Diesel Engine equipped trucks.
Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure.
2. For Diesel engine equipped trucks: Remove the nuts that retain the positive battery cable to the top of the radiator then position the positive battery cable toward the rear.
WARNING: DO NOT REMOVE THE CYLINDER BLOCK PLUG OR THE RADIATOR DRAIN COCK WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR.
3. Without removing the radiator pressure cap and with the system not under pressure, open the radiator draincock by turning it counterclockwise.
4. After the coolant reserve tank has emptied, remove the radiator pressure cap and continue draining the radiator. Save the coolant for later reuse.
5. Remove the upper radiator hose from the radiator.
6. Disconnect coolant reserve/overflow tank hose from radiator fill neck nipple.
7. For Diesel engine equipped trucks: Remove the coolant reserve/overflow tank from the fan shroud by pulling straight up.
8. Disconnect the remove the washer pump from the windshield washer reservoir tank, then drain and remove the tank.
9. Remove the two metal clips retaining the upper part of the fan shroud to the top of the radiator.
10. Remove the four fan shroud mounting bolts (Figure 5). Move the shroud rearward over the fan blades toward the engine.
11. Remove the lower radiator hose.
12. For 8.0L V10 engine equipped trucks: Disconnect and cap the automatic transmission hoses, if equipped.
NOTE: Be careful not to lose the spacer when removing the quick connects.
13. Remove the two upper radiator mounting bolts (Figure 6).
14. Lift the radiator straight up and out of the engine compartment and DESTROY THE RADIATOR BY PUNCTURING SEVERAL OF THE CORES. REMOVED RADIATORS MUST NOT BE REUSED!
15. Transfer the two upper radiator mounting bolt grommets from the removed radiator to the new radiator.
16. Lower the new radiator into position while guiding the two alignment dowels into the lower radiator support.
17. Install the upper radiator mounting bolts. Tighten the screws to 95 in-lbs. (11 N m).
18. Install the fan shroud. Tighten the retaining screws to 50 in-lbs. (5.4 Nm).
19. Install the windshield washer reservoir bottle and install the washer pump.
20. Install the upper and lower radiator hoses. Align the hoses and position the clamps so they will not interfere with the engine or the hood.
21. For 8.0L V10 equipped trucks: Connect the automatic transmission hoses, if equipped.
22. Install the metal clips to the top of the fan shroud.
23. Install the coolant reserve/overflow tank hose to the radiator filler neck nipple.
24. For Diesel engine equipped trucks: Install the positive battery cable to the top of the radiator.
25. Connect the negative battery cable(s).
26. Fill the radiator with the original coolant until full and fill coolant reserve bottle to at least the FULL mark.
NOTE: Be careful not to spill coolant on the drive belts or the generator.
27. Operate engine until it reaches normal operating temperature. Check cooling system and automatic transmission for leaks and proper fluid levels. Adjust as necessary.

Completion Reporting and Reimbursement
Claims for vehicles which have been serviced must be submitted on the DIAL System.

Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments.

Use one of the following labor operation numbers and time allowances:
Labor Operation Time
Number Allowance
Inspect radiator date code 07694181 0.2 hours

Inspect date code and replace radiator:

PL w/SOHC engine 07694182 0.6 hours
PL w/DOHC engine 07694183 1.0 Hours
BR w/ diesel engine 07694184 1.1 hours
BR w/ 8.0L V10 engine 07694185 0.7 hours

Add the cost of the parts package plus applicable dealer allowance to your claim.
Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete claim processing instructions.
Parts Return

NOT REQUIRED -- Removed radiators can not be reused and must be destroyed.

Vehicle Not Available

If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to:

Chrysler Corporation
CIMS 482-00-85
800 Chrysler Drive East
Auburn Hills, Michigan 48326-2757

Following the above procedures will expedite the processing of your claim.

If you have any questions or need assistance in completing this action, please contact your Zone Service Office.

Customer Services Field Operations
Chrysler Corporation