My radiator developed a pin hole leak on my 2003 Dodge where the wire runs to the fan hub across the bottom of the radiator. It looks like I have to remove the supply tubes to the intercooler to make enough room to pull the radiator up and out of the engine bay. What is the best way to do this? I tried removing the intercooler and AC heat exchanger and tried topull off the air tube couplings, but I had two bolts on the intercooler I could not get at to move the intercooler forward. Has anyone tried removing the tubes futher into the engine. Is there enough movement to allow the tubes to move to take of the couplings without moving the intercooler?

Is everyone putting the organic antifreeze back in or are you flushing the sytem and putting traditional ethelyne gycol back in.

Any advice is greatly appreciated.

 

It's a close fit, but you can pull the radiator without removing the intercooler. Remove the fan shroud. Take out the intercooler tubes and the radiator hoses, drop the power steering cooler, loosen the condensor screws and the windshield washer bottle. You can wiggle the driver's side of the radiator up above the intercooler outlet and pull the radiator up on an angle.

 

Thanks for the tip. Do you have any suggestions on removing the intercooler tubes?

 

Loosen the clamps at each end and pull them out. Oops. Forgot to mention you need to remove the airbox also.

 

The radiator came out just like you said. The core has one of the tubes rubbed thin from radiator shroud rubbing where the power cord runs to the fan hub. I read somewhere in the forum that you could split vacuum hose and use that as a spacer on the shrould. Now I will see if a radiator shop can solder or epoxy the core.