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how to replace fan clutch 2003 dodge 2500 cummins?

The procedure is as follows:---

this is a recall problem and faced by many other too.
But still the procedure to replace clutch fan is as follows :---

  • Disconnect the battery negative cables.
  • Remove fan shroud-to-engine bracket nuts.
  • Click image to see an enlarged view
  • View of the fan wiring bracket (1), bracket mounting bolts (2), shroud mounting bracket (3), viscous fan connector (4)-5.9L diesel engine
  • Detach the electronically controlled viscous fan electrical connector from the lower fan shroud bracket.
  • Remove wiring bracket -to-lower fan shroud bracket mounting bolt.
  • Remove fan drive wire harness support from fan shroud.
  • CAUTION Do not remove the fan pulley bolts. This pulley is under spring tension.

    The electronically controlled viscous fan drive/fan blade assembly is attached (threaded) to the fan pulley shaft. Remove the fan blade/fan drive assembly from fan pulley by turning the mounting nut counterclockwise (as viewed from front). Threads on the viscous fan drive are RIGHT- HAND. A 36mm Fan Wrench can be used. Place a bar or screwdriver between the fan pulley bolts to prevent pulley from rotating.

    NOTE It may be necessary to loosen the top two fan shroud brackets. Removal of the engine mounted fan shroud brackets is not necessary unless removing or installing the engine.

    Collapse fan shroud toward front of vehicle and remove fan drive/fan blade and fan shroud as an assembly.

    Click image to see an enlarged view


    Exploded view of the electrical connector (1), viscous fan drive (2), fan blade (3), bolts (4) and radiator fan pulley (5)-5.9L diesel engines

  • Remove the six fan blade-to-viscous fan drive mounting bolts.
  • Inspect the fan for cracked, chipped or damaged fan blades.
  • To install:

    NOTE Viscous Fan Drive Fluid Pump Out Requirement: After installing a new viscous fan drive, bring the engine speed up to approximately 2000 rpm and hold for approximately two minutes. This will ensure proper fluid distribution within the drive.

  • Install fan blade assembly to electrically controlled viscous fan drive. Tighten mounting bolts to 18 ft. lbs. (24 Nm).
  • Loosen both upper engine mounted fan shroud brackets.
  • Make sure lower engine mounted fan shroud bracket bolts are tightened to 18 ft. lbs. (24 Nm).
  • Position fan/fan drive assembly inside fan shroud and lower into position.
  • Install the viscous fan drive assembly onto fan pulley hub shaft . Tighten mounting nut to 85 ft. lbs. (115 Nm).
  • Install fan drive wire harness support to fan shroud.
  • Install viscous fan wiring bracket onto lower fan shroud bracket. Tighten nut to 18 ft. lbs. (24 Nm).
  • Install fan shroud onto fan shroud brackets.
  • Connect fan drive wire harness.
  • Install fan shroud to upper engine fan shroud brackets. Tighten nut finger-tight.
  • Tighten upper engine fan shroud bracket bolts to 18 ft. lbs. (24 Nm).
  • Tighten four fan shroud bracket nuts to 18 ft. lbs. (24 Nm).
  • Make sure of fan tip clearance all the way around inside of fan shroud.
  • Connect the battery negative cables.
  • -------------


    Also for more details read as follows :---


    1.Open the hood.

    2.Obtain a 36 mm fan clutch wrench that is approximately 14" long and that has a square 1/2" drive hole to attach a torque wrench (OTC P/N 7204E2, Snap-on P/N YA9325-1, K-D P/N 3136-76 or MAC P/N FCW3260A). If one of the listed fan clutch wrenches is not readily available, modify the fan clutch wrench from the Cummins Diesel Essential Tool Kit (P/N SP346) as follows:

    a.Remove the red plastic handle cover.

    graphic

    .Mark and center punch a point on the handle that is 12" (300 mm) from the deepest point of the open end (Figure 1).

    c.Using a 7/16" drill bit, drill a hole at the marked location.

    d.In stall a 10-mm bolt and nut combination (PN 06506019AA and PN 06502696 or equivalents) in the handle hole (Figure 1). Tighten the bolt and nut to 75 ft-lbs (102 N.m).

    Using the fan clutch wrench, rotate the radiator cooling fan until the tool handle is approximately vertical. 4.Connect a "clicker" torque wrench to the fan clutch wrench so that the torque wrench and the fan clutch wrench are in a straight line Set the torque wrench to 42 ft-lbs (57 N.m). (This will achieve 85 ft-lbs at the cooling fan nut.)
    IMPORTANT :The torque wrench and the fan clutch wrench MUST be in a straight line to achieve the proper torque measurement.
    NOTE :If using the modified special tool SP346, attach the torque wrench to the bolt that was installed in the handle, with a socket.
    3.

    graphic

    Place a large screwdriver or small pry bar across two of the pulley bolts as shown in Figure 2.

    graphic

    6.While holding the pulley in place with the screwdriver, tighten the cooling fan nut with the torque wrench/fan clutch wrench set to 42 ft-lbs (57 N.m) (Figure 3). This will achieve 85 ft-lbs at the cooling fan nut. NOTE :Turn the nut clockwise, as viewed from the front of the vehicle to tighten. CAUTION :The pulley must be held in place. Belt friction alone will not allow the nut to be tightened sufficiently.7.Remove the torque wrench/fan clutch wrench assembly and the screwdriver. 8.Close the hood.




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    How to Replace a Grille

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-grille.html

    How to Replace a Locking Hub

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-locking-hub.html

    How to Replace a Fender

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-fender.html

    How to Replace a Power Steering Hose

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-power-steering-hose.html

    How to Replace a Tailgate

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-tailgate.html

    How to Replace a Soft Top

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-soft-top.html

    How to Replace a Carburetor

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-carburetor.html

    ­

    How to Replace a Bumper Trim

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-bumper-trim.html

    How to Replace Trunk Strut

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-trunk-strut.html

    How to Replace a Front End Cover

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-front-end-cover.html

    How to Replace a Front Pipe

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-front-pipe.html

    How to Replace an Antenna Mast

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-antenna-mast.html

    How to Replace a Side Marker Light Assembly

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-side-marker-light.html

    How to Install a Carpet on car?

    http://schematicsdiagram.blogspot.com/2011/08/how-to-install-carpet-on-car.html

    How to Replace a Spoiler

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-spoiler.html

    How to Replace a Mirror Glass on car?

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-mirror-glass-on-car.html

    How to Replace a Step Bumper?

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-step-bumper.html

    How to Replace a Door Lock

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-door-lock.html

    How to Replace a Throttle Body

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-throttle-body.html

    How to Replace a Throttle Position Sensor

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-throttle-position-sensor.html

    How to Replace a Grille Insert

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-grille-insert.html

    How to Replace a Fan Shroud Assembly

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-fan-shroud-assembly.html

    How to Replace an Engine Splash Shield

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-engine-splash-shield.html

    How to Replace a Turn Signal Light Assembly

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-turn-signal-light.html

    How to Replace a Headlight Assembly

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-headlight-assembly.html

    How to Replace a Park Light Assembly

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-park-light-assembly.html

    How to Replace an Expansion Tank

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-expansion-tank.html

    How to Replace an Exhaust System

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-exhaust-system.html

    How to Replace a Fender Trim

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-fender-trim.html

    How to Replace a Headlight Door

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-headlight-door.html

    How to Replace a Fan Shroud

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-fan-shroud.html

    How to Replace a Harmonic Balancer

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-harmonic-balancer.html

    How to Replace a Header Panel

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-header-panel.html

    How to Replace a Fuel Tank

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-fuel-tank.html

    How to Replace a Fuel Tank Cap

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-fuel-tank-cap.html

    How to Replace a Distributor

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-distributor.html

    How to Replace an EGR Valve

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-egr-valve.html

    How to Replace an Oxygen Sensor

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-oxygen-sensor.html

    How to Replace an Ignition Wire Set

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-ignition-wire-set.html

    How to Replace a Tail Light

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-tail-light.html

    How to Replace a Door Handle

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-door-handle_18.html

    How to Replace a Hood Strut

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-hood-strut.html

    How to Replace Tail Light Assembly

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-tail-light-assembly.html

    How to Replace a Front Bumper

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-front-bumper.html

    How to Replace a Fuel Pump Assembly

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-fuel-pump-assembly.html

    How to Replace an Axle Assembly

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-axle-assembly.html

    How to Replace a Tailgate Handle

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-tailgate-handle.html

    How to Replace a Wheel Hub Assembly

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-wheel-hub-assembly.html

    How to Replace a Control Arm

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-control-arm.html

    How to Replace a Window Regulator with Motor

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-window-regulator-with.html

    How to Replace a Headlight

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-headlight.html

    How to Check the Brake Fluid Level

    http://schematicsdiagram.blogspot.com/2011/08/how-to-check-brake-fluid-level.html

    How to Replace a Parking Brake Switch

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-parking-brake-switch.html

    How to Replace a Blower Motor Resistor

    http://schematicsdiagram.blogspot.com/2011/08/how-to-replace-blower-motor-resistor.html

    How to replace frost plug on car?

    http://howtobyme.blogspot.com/2011/08/how-to-replace-frost-plug-on-car.html

    Horn stopped working?

    http://howtobyme.blogspot.com/2011/08/horn-stopped-working.html

    How to clean egr valve on Isuzu Amigo?

    http://howtobyme.blogspot.com/2011/08/how-to-clean-egr-valve-on-isuzu-amigo.html

    Cruise control stopped working?

    http://howtobyme.blogspot.com/2011/08/cruise-control-stopped-working.html

    Car is stuck in park and the shift will not move?

    http://howtobyme.blogspot.com/2011/08/car-is-stuck-in-park-and-shift-will-not.html

    How to change the outer door weather strip?

    http://howtobyme.blogspot.com/2011/08/how-to-change-outer-door-weather-strip.html

    Car slows down when it gets hotter?

    http://howtobyme.blogspot.com/2011/08/car-slows-down-when-it-gets-hotter.html

    Warning lights on and speedometer died?

    http://howtobyme.blogspot.com/2011/08/warning-lights-on-and-speedometer-died.html

    Car won't rev past 1900 rpms?

    http://howtobyme.blogspot.com/2011/08/car-wont-rev-past-1900-rpms.html

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