Flex-a-Lite 262 Installation Instructions

Dual Electric Fan #262
Fits 1994-2002 Dodge 2500/3500 w/ 5.9L Cummins Diesel

INSTALLATION INSTRUCTIONS

REMOVE EXISTING FAN & SHROUD:
1. Disconnect battery negative (-) cable from both batteries.
2. Make sure the engine is cool! Open the radiator cap slightly to release the
vacuum. Using the radiator valve drain located on the driver's side, drain
enough coolant to clear the upper inlet hose of coolant. A hose or funnel will
help reduce spillage.
3. Using a 10mm socket or wrench, remove secondary battery positive (+)
cable that runs along the top of the radiator. FOR YOUR SAFETY, discon-
nect cable completely from both batteries!! see detail 1.
4. Disconnect coolant overflow bottle tube from radiator next to radiator cap.
5. Remove coolant overflow bottle from shroud by pressing on the round
"button" located at the backside of the bottle towards the shroud while lifting
up on the bottle at the same time.
6. Remove upper hose from radiator and hold off to the side for clearance.
7. Disconnect the windshield wash reservoir from the shroud by pressing the 2
locking "buttons" on the backside of the the tank towards the shroud and
lifting up at the same time. It is not required to remove the tank entirely, just
hold tank off to the side. see detail 2.
8. Using 10mm socket, remove the 4 bolts (2 left side and 2 right side) that
hold the shroud in place. KEEP these bolts for installation of new fan.
9. Remove 2 small clips that hold the top of the factory shroud to the top of
the radiator.
10. Locate lower wire harness fastened to the lower part of the factory
shroud. Unfasten harness from the factory shroud. NOTE: Do not disconnect
harness from electrical system
11. Remove OEM clutch fan. This can be accomplished by turning the large
nut on the engine side of the fan clockwise. NOTE: Careful not to let the fan
hit the radiator core when it is spun loose from the engine.
12. Lift out the fan and shroud together to avoid any damage to the radiator
core.
INSTALLATION:
1. Start by attaching the side brackets to the shrouds with hex bolts and lock
nuts provided. see detail 3.
2. Place the coolant overflow bottle on the new shroud by aligning the tab on
the bottom of the bottle with the support tab on the bottom of the shroud. Push
bottle into shroud and slide down to lock in place.
3. Locate the temperature sensor in the kit bag. Insert the temperature sensor
into the radiator fins near the radiator inlet. Leave 1/4" or less protruding
from the surface of the radiator for optimum performance. The wires will
run out through the top corner of the fan shroud. These will be used later
while wiring the VSC. see detail 4.
DETAIL #1
DETAIL #2
98262 page 1 of 4 rev . 03-24-08