Remove Front Shroud Assembly and Radiator Remove Stock Fan

Remove Front Shroud Assembly and Radiator Remove Stock Fan
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#59074 Ford 03-07 6.0L Super Duty Diesel Radiator
#59274 Ford 03-07 6.0L Super Duty Diesel
Radiator/Fan Combo
#59274 Ford 03-07 6.0L Super Duty Diesel
Radiator/Fan Combo Without VSC
Fits MOST Ford 6.0L Super Duty Diesels, 2003-2007
(Note: Automatic transmissions may require auxiliary oil
cooler part # 41124RC. Vehicle models may vary; review the
instructions and components for compatibility with your
vehicle prior to installation.)
Scan here with your smartphone to see a step-by-step install video
or type http://youtu.be/T3dsdh0CEfw into your favorite browser
Remove Front Shroud Assembly and Radiator
1. Make sure engine is cool.
2. Disconnect negative (-) battery cable from battery.
3. Drain radiator coolant.
4. Undo 4 ea. 5/16” bolts from brackets holding top posts
of radiator and remove.
5. Remove 4 tree clips holding plastic panel around hood
latch to radiator.
6. Remove tree clips holding positive (+) battery cable to
front radiator support.
12. Pull top of radiator toward grille and lift front
section of shroud.
NOTE: The bottom of this shroud piece has a
rubber flap that may need to be lifted out of the
way to move front section of shroud up and out.
13. Unplug clutch fan connector at the top of the rear
shroud section closest to engine.
14. Remove lower radiator hose and transmission lines
if applicable.
15. Remove radiator by lifting straight up and out of
the vehicle.
Fig. 2
7. Remove clip straps holding positive (+) battery cable
to radiator on both sides. (Fig. 1)
8. Move positive (+) battery cable out of the way of
radiator.
9. Remove top radiator and overflow hoses.
10. Below vehicle, disconnect mounting strap tree clip
from radiator shroud. (Fig. 2)
11. Remove 2 ea. 5/16” bolts holding top of shroud to
top of radiator.
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Fig. 1
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Remove Stock Fan and Rear Shroud Assembly
1. Remove 4 ea. 15MM bolts holding rear shroud to the
engine.
2. Pull rear shroud forward to access the nut attaching the
clutch fan.
3. Secure the clutch fan pulley with a pry bar and loosen
nut with a large adjustable wrench.
4. Remove the rear shroud and clutch fan assembly at the
same time from the engine compartment.
Install New Flex-a-Fit® Radiator
1. Lower radiator into engine bay. Align radiator posts
with lower radiator support mounts.
2. Place 2 t-bolts in the second t-channel from the
engine. Line t-bolt up with the fctory top mounting
bracket location.
3. Thread included aluminum posts onto T-Bolts and
tighten with a 9/16” wrench.
4. Place 3 t-bolts into topmost t-channel on front of
radiator facing grille. Attach top mounting brackets,
leaving a 1/8” gap between the radiator tank and the core
support.
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5. Remove/cut the taped t-shaped push clips on the
positive (+) battery cable.
6. Use included insulated metal clamps to attach battery
cable to t-bolts. Secure with 1/4”-20 lock nuts.
7. Attach upper hose and overflow hose to radiator.
8. Attach lower radiator hose.
9. Rotate mounting strap 180° and push both tree clips
into mounting holes on Flex-a-Lite aluminum fan shroud.
10. Fill radiator through overflow bottle with factory
recommended coolant.
Fan Wiring Instructions
Mount and Install Clutch Fan Emulator
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. Mount emulator facing down on bracket #51313 with
supplied screws.
2. Bolt bracket to factory mounting location near
windshield. (Fig. 3)
3. Plug emulator directly into factory fan clutch socket.
Fig. 3
98275 Rev. 01-22-14
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Controller Wiring
1. Using the large yellow butt connectors provided, attach
a length of the thick (10 AWG) red wire to the orange motor wires at the fan.
2. Attach a length of the thick (10 AWG) black wire to
the black motor wires at the fan. Once the fan is in place,
these will attach to the control unit.
Connect Power Leads
1. Determine the length needed to run thick red and black
wire from the VSC to the battery terminals and trim
appropriately.
2. Crimp a large yellow ring connector to one end of each
wire and connect the black wire to the negative (-) battery
terminal, but DO NOT connect the red wire yet!
3. Using butt connectors, connect the fuse holder provided
inline with the red wire.
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Ignition-controlled Power Source
1. Locate the fuse box.
2. Find a circuit that is hot when the key is in the ON
position.
3. Attach the included fuse tap to the fuse. Attach a
female connector to the thin red wire included and
connect to the fuse tap.
4. Attach pink female connector to end of the wire and
connect to terminal #9 on VSC.
NOTE:DO NOT use the DRL or brake/taillight fuse!
NOTE: On Radiator/Fan Kit #59274 the
VSC is pre-wired to the fans for ease of
installation. Verify that the pre-wired
components are correctly hooked up,
then proceed to connect the remaining
wires necessary for your install.
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Reassemble And Test
1. Insert temp. probe near radiator inlet, leaving 1/4” of
the probe sticking out from the core. Be careful not to
damage radiator core.
2. Turn Ignition on. If the LED farthest from VSC power
wires does not turn on after 6 seconds, check 12V power
going to terminal #9.
3. With engine running, turn A/C on. The fan should be
running and 3 of the LEDs should be lit. If not, verify A/C
clutch is engaged and correct signal wire is triggered.
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3. Turn A/C off. Let vehicle warm up to normal operating
temperature. Adjust screw terminal clockwise to increase
turn-on temperature and counter-clockwise to decrease
temperature. NOTE: THE SCREW TERMINAL ONLY
ROTATES 3/4 OF A TURN. IF TURNED BEYOND ITS
LIMITS THE TERMINAL WILL BREAK!
4. Once desired temperature is set, let the engine idle
and make sure the fan cycles to maintain desired
temperature. Make sure the fan is pulling air through
the radiator toward the engine.
5. Reassemble vehicle and top off coolant.
What’s Next?
Register your product for warranty at
http://automotive.flex-a-lite.com/warranty-registration/
Enjoy your Flex-a-lite performance cooling product!
If you need further assistance, please contact tech services
at 253-922-2700 M-F 8:00am-5:00pm PST.
The Flex-a-lite Limited Warranty
Flex-a-lite Consolidated, 7213-45th St. Ct. E. Fife, WA 98424,
Telephone No. 253-922-2700, warrants to the original purchasing user,
that all Flex-a-lite products to be free of defects in material and
workmanship for a period of 365 days (1 year) from date of purchase.
Flex-a-lite products failing within 365 days (1 year) from date of
purchase may be returned to the factory through the point of
purchase, transportation charges prepaid. If, on inspection, cause of
failure is determined to be defective material or workmanship and not
by misuse, accidental or improper installation, Flex-a-lite will replace
the fan free of charge, transportation prepaid. Flex-a-lite will not be
liable for incidental, progressive or consequential damages. Some
states do not allow the exclusion or limitation of incidental or
consequential damages, so the above limitation or exclusion may not
apply to you. This warranty gives you specific legal rights and you may
have other rights, which vary from state to state. The Flex-a-lite warranty
is in compliance with the Magnuson-Moss Warranty Act of 1975.
98275 Rev. 01-22-14
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