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Dual Electric Fan #264

Rev. 05-14-13 #98264 page 1 of 4

DETAIL #1

DETAIL #2

REMOVE EXISTING FAN & SHROUD:

Make sure the engine is cool!1.

Disconnect battery negative (-) cable from both batteries.2.

Dismount windshield washer tube and battery cable from top of shroud 3.

(3 plastic clips). See detail 1

On passenger side, use 10mm socket, loosen air box front mounting 4.

point. See detail 2

Remove 2-13mm bolts (one on each side) from top of shroud attached

to radiator.

Note: To access bolt on passenger side, slide air box backwards. You may

need to disconnect overow tube as well. See detail 3

Hold back rubber ap at the top of “oating/stock” shroud. Using spring 6.

clamps can assist to keep ap from snapping back into your way. See

detail 4

Pull partial radiator side shroud out slowly from above.7.

From below, disconnect electric clutch from harness; use at-head screw 8.

driver to unlock connector. Harness can be found near mounting bracket

of “oating” shroud on driver’s side. See detail 5

Note: By disconnecting the electric clutch, this may cause your check

engine light to illuminate after start-up. See dealer to clear check

engine light.

Un-mount electric clutch wire mount using 10mm socket. Wire mount will 9.

be attached to lower bracket of “oating” shroud on driver’s side.

See detail 6

Suggestion: Cut piece of cardboard (27” x 29” & tape to inside of core for

radiator protection).

Remove 2-13mm nuts securing top half of “oating” shroud, allowing shroud 10.

to lean toward radiator core. This gives enough room for “fan clutch

mounting-nut” accessibility.

From below, remove 2-13mm nuts securing bottom of “oating” shroud 11.

to bottom bracket.

While holding clutch pulley, use 36mm wrench & turn counter-clockwise 12.

to loosen fan clutch mounting-nut. Be careful not to drop fan & clutch

assembly as it unscrews from pulley.

Slowly13. pull fan & clutch assembly up simultaneously with “oating”

shroud. Make sure electric clutch wire mount is free from snagging on

bottom “oating” shroud bracket. Remove top & bottom “oating”

shroud brackets.

Note: Top bracket on passenger’s side secures wiring loom. Find alternate mounting point near by and re-

secure. The 2 top brackets & 1 bottom bracket.

Note: Removal of “oating” shroud mounting brackets is for appearances only.

There should be enough

clearance to install new shroud without removal of brackets.

DETAIL #3

INSTALLATION INSTRUCTIONS

(Meets recommended factory GCVW ratings)

**Before installation of your Flex-a-lite fan, be sure that your batteries and charging

system are operating correctly. Poor batteries or charging system may result in the fan

or controller to function improperly.**

Fits 2003-2008 Dodge 2500/3500

w/ 5.9L & 6.7L Cummins Diesel

Summary of content (4 pages)

PAGE 1
Dual Electric Fan #264 Fits 2003-2008 Dodge 2500/3500 w/ 5.9L & 6.7L Cummins Diesel (Meets recommended factory GCVW ratings) **Before installation of your Flex-a-lite fan, be sure that your batteries and charging system are operating correctly. Poor batteries or charging system may result in the fan or controller to function improperly.** INSTALLATION INSTRUCTIONS REMOVE EXISTING FAN & SHROUD: 1. Make sure the engine is cool! 2. Disconnect battery negative (-) cable from both batteries. 3.
PAGE 2
DETAIL #4 DETAIL #5 DETAIL #6 INSTALLATION OF ELECTRIC FAN & SHROUD: 1. Start by attaching passenger side bracket to the shroud with 10mm hex bolts and lock nuts (3ea). see detail #1 2. Gently lower the fan/shroud into the vehicle placing the lower tab of the mounted bracket into the side tank slot on passenger side. Slot is at bottom of radiator molded onto side tank. Examine old shroud tabs for reference. 3.
PAGE 3
WIRING THE FAN MOTOR CONTROL CONTINUED WIRING THE FAN MOTOR CONTROL FOLLOW THESE INSTRUCTIONS CAREFULLY TO AVOID DAMAGING THE CONTROL UNIT, FAN MOTORS, AND YOUR VEHICLE! WHEN CRIMPING WIRES, ALWAYS USE A QUALITY CRIMPING TOOL (DO NOT USE PLIERS OR OTHER DEVICES). 1. Find the thick red and black wire bundles in the wiring kit.
PAGE 4
Wiring Diagram Initial Start-up and Adjustment Procedures 1. Turn ignition on. After 6 seconds, LED #L4 should light up. If not, check to make sure that there is 12 volts at terminal #9 on the Fan Motor Control. The delay is to allow the starter to start the vehicle without the fans drawing any power. 2. With the engine running, engage the A/C. The fans should come on and cycle with the A/C clutch. LED’s #L1, L3 and L4 should be lit when the fans are running.