Owners manual

ManualsBrandsFlex-A-Lite ManualsAutomotiveFlex-a-lite 264 Full Size Diesel Truck Electric Fan

Dual Electric Fan #264

Fits 2003-2008 Dodge 2500/3500 w/ 5.9L & 6.7L Cummins Diesel

INSTALLATION INSTRUCTIONS

98264 page 1 of 4 01-15-10

DETAIL #1

DETAIL #2

REMOVE EXISTING FAN & SHROUD:

1. Make sure the engine is cool!

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

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

shroud (3 plastic clips).

See detail 1

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

mounting point.

See detail 2

5. 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 overflow tube as well.

See detail 3

6. Hold back rubber flap at the top of “floating/stock” shroud. Using

spring clamps can assist to keep flap from snapping back

into your way.

See detail 4

7. Pull partial radiator side shroud out

slowly

from above.

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

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

of “floating” shroud on driver’s side.

See detail 5

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

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

See detail 6

Suggestion:

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

radiator protection).

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

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

mounting-nut” accessibility.

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

shroud to bottom bracket.

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

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

assembly as it unscrews from pulley.

13.Slowly

pull

fan & clutch assembly up simultaneously with “floating”

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

bottom “floating” shroud bracket.

Remove top & bottom “floating” 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 “floating” shroud mounting brackets is for appearances only. There should be

enough clearance to install new shroud without removal of brackets.

DETAIL #3

DETAIL #4

DETAIL #5

DETAIL #6

Summary of content (4 pages)

PAGE 1
Dual Electric Fan #264 Fits 2003-2008 Dodge 2500/3500 w/ 5.9L & 6.7L Cummins Diesel INSTALLATION INSTRUCTIONS REMOVE EXISTING FAN & SHROUD: 1. Make sure the engine is cool! 2. Disconnect battery negative (-) cable from both batteries. 3. Dismount windshield washer tube and battery cable from top of shroud (3 plastic clips). See detail 1 4. On passenger side, use 10mm socket, loosen air box front mounting point. See detail 2 5. Remove 2-13mm bolts (one on each side) from top of shroud attached to radiator.
PAGE 2
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. While holding up driver’s side, insert factory 13mm bolt securing top of bracket to side tank mount on passenger’s side. 4.
PAGE 3
WIRING THE VARIABLE SPEED CONTROL CONTINUED 4. Crimp a large ring connector to the positive (+) battery end of the power lead and connect it to the battery terminal (secondary battery on passenger side). 5. Locate power distribution box (fuse box). Find a circuit that is “hot” when the key is in the “ON” position. NOTE: DO NOT use the DRL or brake/ taillight fuse! Attach the included fuse tap to the fuse. Attach a pink female connector to the thin red wire included and attach to the fuse tap.
PAGE 4
WIRING CONTINUED FROM PAGE 3 The Variable Speed Control has new features. At the set temperature, the fans will come on at 60%; this reduces the load on your charging system. If the temperature rises, the fan speed will increase. If your set temperature is 195°F, then between 195° and 205° the fan speed will increase from 60% to 100%. So after a 10° rise from the set point, the fans will be running at 100%. Initial Start-up and Adjustment Procedures 1. Turn ignition on.