Dodge ram truck 3500 1996 Service Manual page 333

B R
COOLING SYSTEM 7 - 49
REMOVAL AN© INSTALLATION (Continued)
(1) Disconnect both negative battery cables from
both batteries.
(2) Remove accessory drive belt. Refer to Belt
Removal/Installation in the Engine Accessory Drive
Belt section in this group.
(3) Drain cooling system until coolant level is
below thermostat. Refer to Draining Cooling System
in this section.
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094) (Fig. 23). SNAP-ON CLAMP TOOL (NUMBER
HPC-20) MAY BE USED FOR LARGER CLAMPS.
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC­
ING CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps (Fig. 24). If
replacement is necessary, use only an original
equipment clamp with a matching number or letter.
(4) Remove radiator hose clamp and hose from
thermostat housing. A special clamp tool (Fig. 23)
must be used to remove the constant tension clamps.
(5) Remove the hose clamp and check valve hose
at thermostat housing (Fig. 76).
HOUSING
HOSE
LIFT
BRACKET
H O U S I N G
BOLTS
OUTER THERMOSTAT
SEAL
INNER
SEAL
J9507-22
Fig. 76 Thermostat Removal—5.9L Diesei
(6) Remove the two upper generator bracket
mounting bolts (Fig. 77).
(7) Remove the upper generator mounting bracket
(Fig. 77).
(8) Loosen but do not remove the generator lower
pivot bolt.
(9) Position the generator to gain access to thermo­
stat housing and housing bolts.
(10) Remove thermostat housing mounting bolts.
BRACKET
SOUS
MOUNTING
BRACKET
GENERATOR
J9407-13
Fig. 77 Generator Mounting Bracket Bolts—Diesei
(11) Remove the thermostat housing, thermostat,
inner and outer seals and lift bracket (Fig. 76).
(12) Clean the mating surfaces of the thermostat
housing and the cylinder head.
mSWMLLMTIOm
(1) Install the outer seal (Fig. 76) (Fig. 78)into the
machined shoulder on the thermostat housing.
(2) Install the thermostat into the machined shoul­
der next to the outer seal. Note direction of thermo­
stat in (Fig. 76) (Fig. 78).
(3) Position the inner thermostat seal with the
shoulder towards the thermostat housing (Fig. 78).
LIFT
BRACKET
THERMOSTAT
OUTER
SEAL SHOULDER J9507-23
Fig. 78 Thermostat Seals—5.9L Diesel—Typical